Download Magnum Energy MCP5538 Owner`s manual

Mini Magnum Panel (MMP)
Owner’s Manual
Disclaimer of Liability
The use of this manual and the conditions or methods of installation, operation, use and maintenance
of the MMP enclosure is beyond the control of Magnum Energy, Inc.. Therefore, this company
does not assume responsibility and expressly disclaims liability for loss, damage, or expense,
whether direct, indirect, consequential or incidental, arising out of or anyway connected with such
installation, operation, use, or maintenance.
Due to continuous improvements and product updates, the images shown in this manual may not
exactly match the unit purchased.
Restrictions on Use
Magnum Energy, Inc. does not recommend the use of any of its products with life support systems,
life saving, or other medical equipment or devices designated as “critical” by the U.S. FDA where
failure or malfunction of the Magnum Energy product can be reasonably expected to cause failure
of the life support device, or to significantly affect its safety or effectiveness. Using Magnum Energy
products with this particular equipment is at your own risk.
Copyright Notice
Copyright © 2010 by Magnum Energy, Inc. All rights reserved. Permission to copy, distribute and/or
modify this document is prohibited unless express written permission from Magnum Energy, Inc.
is provided.
Contact Information
Magnum Energy, Inc.
2211 West Casino Rd.
Everett, WA 98204
Phone: 425-353-8833
Fax: 425-353-8390
Web: www.magnumenergy.com
Statement of Appreciation
From all of us at Magnum Energy Thank you for purchasing this Mini Magnum Panel (MMP).
We understand that you have many purchasing options in the marketplace, and are pleased that
you have decided on a Magnum Energy product. This MMP enclosure was proudly assembled and
tested in the United States in our Everett, Washington facility.
At Magnum, we are committed to providing you with quality products and services; and hope that
your experience with us is pleasant and professional.
Magnum Energy® is a registered trademark of Magnum Energy, Inc.
Page i
© 2010 Magnum Energy, Inc.
Table of Contents
1.0
Safety Information ............................................................................................ 1
1.1
Safety Symbols ......................................................................................... 1
1.2
General Safety .......................................................................................... 1
1.3
Battery Safety ........................................................................................... 2
2.0
Introduction ...................................................................................................... 3
2.1
MMP Series Overview ................................................................................. 4
2.2
MMP External Components .......................................................................... 5
2.3
MMP Internal Components .......................................................................... 6
3.0
Installation ...................................................................................................... 10
3.1
Preparation ..............................................................................................10
3.2
Location ..................................................................................................12
3.3
Conduit Knockouts ....................................................................................12
3.4
Mounting .................................................................................................14
3.5
Wiring the MMP Enclosure - General Requirements ........................................16
3.6
Torque Requirements ................................................................................17
3.7
Electrical System Wiring Diagrams ..............................................................17
3.8
DC Wiring ................................................................................................20
3.9
AC Wiring ................................................................................................28
3.10 MMP/Inverter System Grounding ................................................................37
3.11 Removing the AC Neutral to Ground Connection ............................................41
3.12 Removing the DC Negative to Ground Connection .........................................41
3.13 Wiring Accessories ....................................................................................42
3.14 Installation Checklist .................................................................................44
3.15 Functional Test .........................................................................................46
4.0
Operation ........................................................................................................ 48
4.1
Inverter DC Disconnect Breaker ..................................................................49
4.2
AC Input Breaker ......................................................................................49
4.3
Inverter AC Output Breaker........................................................................49
4.4
Inverter AC Bypass Switch Breaker .............................................................49
Appendix A
A-1
A-2
A-3
A-4
A-5
- Optional Equipment and Accessories .................................................... 52
Installing a Remote Control ........................................................................52
Installing a Battery Monitor ........................................................................53
MMP Backpanel Information .......................................................................54
Installing Optional DC Breakers ..................................................................55
Installing Lightning Arrestors......................................................................57
Appendix B - Warranty and Service ........................................................................... 59
B-1
Limited Warranty ......................................................................................59
B-2
How to Receive Repair Service ....................................................................59
© 2010 Magnum Energy, Inc.
Page ii
List of Figures
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Figure
Figure
Figure
Figure
2-1, MMP Outside Components ............................................................................. 5
2-2, MMPxxx-30D Internal Components ................................................................. 8
2-3, MMPxxx-30D AC Breakers ............................................................................. 8
2-4, MMPxxx-60S Internal Components ................................................................. 9
2-5, MMPxxx-60S AC Breakers.............................................................................. 9
3-1, MMP Series Simplified Installation Diagram .....................................................11
3-2, MMP Series Dimensions and Knockout Location/Sizes .......................................13
3-3, Removing Knockouts ...................................................................................14
3-4, Keyhole Locations for Mounting .....................................................................15
3-5, MMPxxx-30D System Wiring Diagram.............................................................18
3-6, MMPxxx-60S System Wiring Diagram .............................................................19
3-7, DC Wiring Connection Points .........................................................................21
3-8, DC Wiring with Magnum Inverter ...................................................................22
3-9, DC Wiring with non-Magnum Inverter ............................................................23
3-10, DC Connections - with Magnum Inverter Installed ..........................................25
3-11, DC Connections - without Magnum Inverter Installed .....................................26
3-12, AC Wiring Connections (MMPxxx-30D Models) ...............................................29
3-13, AC Wiring Connections (MMPxxx-60S Models) ...............................................30
3-14, AC Wiring for Single In - Single Out (30 A) Configurations ..............................33
3-15, AC Wiring for Single In - Single Out (60 A) Configurations ..............................34
3-16, AC Wiring for Dual In - Single Out Configurations ..........................................35
3-17, AC Wiring for Dual In - Dual Out Configurations .............................................36
3-18, Grounding System for Inverter with MMP Enclosure........................................37
3-19, Single Connection to DC Ground Rod (Method 1) ...........................................38
3-20, Multiple Connections to DC Ground Rod (Method 2)........................................39
3-21, Multiple Connections to DC Ground Rod (Method 3)........................................39
3-22, Removing the AC Neutral to Ground Connection ............................................41
3-23, Removing the DC Negative to Ground Busbar ................................................41
3-24, REMOTE Communication Cable (300V) .........................................................42
3-25, NETWORK Communication Cable (300V) .......................................................42
3-26, Extension Cable (300V) ..............................................................................42
3-27, Accessory Wiring using 300 Volt Communications Cables ................................43
3-28, AC Voltage Checks .....................................................................................47
4-1, MMP Functional Diagram ..............................................................................48
4-2, MMPxxx-30D Bypass Switch Operation ...........................................................50
4-3, MMPxxx-60S Bypass Switch Operation ...........................................................51
A-1, Installing a Remote Control on the MMP Enclosure ...........................................52
A-2a, Mounting the Sense Module ........................................................................53
A-2b, Wiring the Sense Module and DC Shunt ........................................................53
A-3, MMP Backpanel (BP-MMP) Information ...........................................................54
A-4a, Installing DIN Rail Mounted DC Breakers ......................................................55
A-4b, Installing Backpanel Mounted DC Breakers ....................................................56
A-4c, Wiring DC Breakers ....................................................................................56
A-5a, Installing Lightning Arrestor on MMP Enclosure ..............................................57
A-5b, Wiring Lightning Arrestor to MMP Enclosure ..................................................58
List of Tables
Table
Table
Table
Table
Table
Table
Table
3-1,
3-2,
3-3,
3-4,
3-5,
3-6,
3-7,
Page iii
Torque Values for Busbars ..............................................................................17
Torque Values for the DC Shunt and DC Disconnect Breaker ...............................17
Torque Values for the AC Terminal Blocks .........................................................17
Recommended DC Wire to MMP enclosure ........................................................24
AC Input/Output Wiring Configurations ............................................................32
AC Grounding Electrode Conductor Sizing ........................................................38
Equipment Grounding Conductor Sizing ...........................................................40
© 2010 Magnum Energy, Inc.
1.0 Safety Information
1.0
Safety Information
IMPORTANT SAFETY INSTRUCTIONS
This manual contains important safety instructions that must be followed during the installation
and operation of this product. Before using the Mini Magnum Panel (MMP), read all instructions
and cautionary markings on: (1) the MMP Enclosure, (2) the inverter/charger, and (3) the batteries
in this manual as well as the individual manuals provided for each component of the system.
These installation instructions are for use by qualified personnel only. Do not perform any
installation or servicing other than that specified in this Owner’s manual unless you are qualified
to do so. Incorrect installation or servicing may result in a risk of electric shock, fire, or other
safety hazard.
1.1
Safety Symbols
The following safety symbols have been placed throughout this manual to indicate dangerous
conditions and important safety instructions.
WARNING: This symbol indicates that failure to take a specified action could result in
physical harm to the user.
CAUTION: This symbol indicates that failure to take a specified action could result in
damage to the equipment.
Info: This symbol indicates information that emphasizes or supplements important
points of the main text.
1.2
General Safety
•
All electrical work must be performed in accordance with local and national electrical codes.
•
This product is designed for indoor/compartment installation. It must not be exposed to rain,
snow, moisture or liquids of any type.
•
Use insulated tools to reduce the chance of electrical shock or accidental short circuits.
•
Remove all jewelry such as rings, watches, bracelets, etc., when installing or performing
maintenance on the inverter.
•
Both AC and DC overcurrent protection must be provided as part of the installation.
•
Use Class 1 wiring methods for field wiring connections to terminals of a Class 2 circuit.
•
Listed or labeled equipment shall be installed and used in accordance with any instructions
included in the listing or labeling.
•
To reduce risk of electric shock, disconnect all wiring before attempting any maintenance or
cleaning. Turning off the inverter will not reduce this risk, the inverter bypass must be used or
the panel should be totally disconnected from all sources.
•
All wiring must have a minimum rating of 300V, 75°C. AC wiring must be no less than 10 AWG
(5.3 mm2) gauge copper wire. Battery cables should be no less than #4/0 AWG for 12 and
24 volt systems and #2/0 AWG gauge for 48 volts systems. Crimped and sealed copper ring
terminal lugs with a 3/8 hole should be used to connect to the DC terminals inside the MMP
enclosure. Soldered cable lugs are also acceptable.
•
Torque all AC wiring connections and DC cable connections to the required torque values.
READ AND SAVE THESE INSTRUCTIONS
© 2010 Magnum Energy, Inc.
Page 1
1.0 Safety Information
1.3
Battery Safety
IMPORTANT BATTERY SAFETY INSTRUCTIONS
•
Be very careful when working around batteries, they can produce extremely high currents if
short-circuited. Read the battery supplier’s precautions before installing and connecting the
inverter and batteries.
•
Wear eye protection such as safety glasses when working with batteries.
•
Remove all jewelry such as rings, watches, bracelets, etc., when installing or performing
maintenance on the batteries.
•
Never work alone. Always have someone near you when working around batteries.
•
Use proper lifting techniques when working with batteries.
•
Never use old or untested batteries. Check each battery’s label for age, type, and date code
to ensure all batteries are identical.
•
Batteries are sensitive to changes in temperature. Always install batteries in a stable
environment.
•
Install batteries in a well ventilated area. Batteries can produce explosive gasses. For
compartment or enclosure installations, always vent batteries to the outside.
•
Provide at least one inch of air space between batteries to provide optimum cooling.
•
Never smoke when in the vicinity of batteries.
•
To prevent a spark at the battery and reduce the chance of explosion, always connect the
cables to the batteries first. Then connect the cables to the MMP enclosure/inverter system.
•
Use insulated tools at all times.
•
Always verify proper polarity and voltage before connecting the batteries to the MMP enclosure/
inverter system.
•
To reduce the chance of fire or explosion, do not short across the battery terminal.
•
In the event of accidental exposure to battery acid, wash thoroughly with soap and water. In
the event of exposure to the eyes, flood them for at least 15 minutes with running water and
seek immediate medical attention.
•
Recycle old batteries.
•
Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short-circuit
the batteries or other electrical parts, resulting in sparks that could cause an explosion.
•
Cover the terminals to prevent accidental shorting.
READ AND SAVE THESE INSTRUCTIONS
Page 2
© 2010 Magnum Energy, Inc.
2.0 Introduction
2.0
Introduction
Congratulations on your purchase of the Mini Magnum Panel (MMP) enclosure, part of a new line of
Panel Systems from Magnum Energy. Installing an inverter system is now as simple as mounting
the MMP enclosure, installing the inverter, connecting the battery bank, and if needed, bringing in
AC power from a generator or the utility. The inverter’s required AC and DC disconnects and wire
connection points are all together, and integrated in one self-contained MMP enclosure.
This unit has been specifically designed to combine all of the major components required for a
renewable energy system — inverter/battery disconnect, AC overcurrent protection, grounding
connections, and a full system inverter bypass switch as a convenient way to isolate the inverter
for battery maintenance — into a single, easy to install pre-wired enclosure.
Designed for single inverter applications, the MMP enclosure features convenient front panel operation, and with the optional front panel remote, allows you to easily set up, monitor, and operate
your Magnum inverter system. In addition to saving time and money by providing a simple and
convenient inverter installation, the MMP enclosure ensures safety and reliability by providing a
UL and CSA certified and code compliant system.
What makes the MMP enclosure stand out from the competition?
• It is engineered to combine the convenience and cost savings of a pre-wired, factory-integrated
system with the flexibility of a single person, field installable power system.
• The self-contained enclosure system approach is convenient and space-saving, reducing
installation time and cost compared to a conventional approach using multiple interconnected
components.
• The MMP enclosure can be combined at the factory with a Magnum Energy inverter that has
been pre-wired and tested as a complete system, ensuring reliable and consistent performance
meeting National Electric Code requirements with UL listed components.
•
Four models are available to meet the flexibility and power demands of your application.
• Specifically designed to fit Magnum inverters, but easily adaptable to connect other inverter
systems in 12, 24, or 48 VDC standardized configurations.
• Includes a built-in AC maintenance bypass switch and a DC disconnect breaker for safe and
convenient servicing of the inverters and/or battery bank.
• Additional space to install up to eight ½” (12.7mm) wide DIN rail mounted breakers or four 1”
(25.4mm) wide back mounted breakers for use as DC load breakers, PV disconnects, or to install
PV-Ground Fault Protection (PV-GFP).
• A full system capacity DC shunt (500 amps) installed to allow easy connection to a state-ofcharge battery monitor.
• All AC/DC wiring connections and AC/DC circuit breaker operations are easily accessible from
the front.
•
Additional accessories can be installed inside.
• The enclosure is powder coated for durability and to help prevent corrosion, and includes
conduit knockouts for connection to the batteries, PV, generator, or other AC/DC sources.
Regulatory Compliance
The MMP enclosure is designated as Interconnection System Equipment (ISE) for use with inverters.
It has been tested and certified by Intertek Testing Services (known as ETL) to UL 1741, 1st Edition,
and is also CSA certified to C22.2 No. 107.1-01 (R2006) for product safety and compliance to the
National Electric Code in the US and the Canadian Electrical Code in Canada.
ETL is a Nationally Recognized Testing Laboratory (NRTL). NRTL’s are qualified organizations that
meet the requirements of Occupational Safety and Health Administration (OSHA) regulations to
perform independent safety testing and product certification.
© 2010 Magnum Energy, Inc.
Page 3
2.0 Introduction
2.1
MMP Series Overview
The MMP enclosures are available in four basic configurations; this section lists the four models
and the main components and features.
Individual Models:
•
•
•
•
MMP175-30D (Mini Magnum Panel, 175 ADC breaker, dual 30 AAC bypass/input breakers)
MMP175-60S (Mini Magnum Panel, 175 ADC breaker, single 60 AAC bypass/input breakers)
MMP250-30D (Mini Magnum Panel, 250 ADC breaker, dual 30 AAC bypass/input breakers)
MMP250-60S (Mini Magnum Panel, 250 ADC breaker, single 60 AAC bypass/input breakers)
Standard Features:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Enclosure is steel construction with durable white powder coat finish
Battery/inverter DC disconnect breaker (175 or 250 amp)
Inverter AC input overcurrent protection breakers
Pre-wired AC bypass switch for inverter isolation/battery maintenance
Front mount AC and DC breakers for quick and easy operation
AC and DC Ground screw type compression terminals (no lugs required)
500A/50mV DC shunt installed for easy connection to Battery Status monitor
Easy field wiring with front mounted AC and DC input/output terminals
Enclosure and components are UL/CSA certified and designated for indoor use
Configurations available for both single 120VAC and 120/240VAC systems
DC negative and ground busbars (negative can be isolated if PV-GFP device installed)
Battery positive busbar for DC loads and PV arrays included
Provides mounting for DIN rail or back-mounted DC load/disconnect breakers
Integrates directly with Magnum ME, MS, MS-PAE, and RD Series inverters
Top cover plate provided to allow other (non-Magnum) inverter installations
Knockouts for inverter and battery cables, PV in/out, DC breakers
Stud terminal available for large DC wire if used as system ground
Data cables with 300 volt rated insulation provided to allow 240 VAC inverter installations
Inverter hood provided to allow a Magnum inverter to be mounted vertically
Physical Features:
•
•
•
•
MMP Dimensions (H x W x D): 18” x 13” x 6.75” (45.7cm x 33cm x 17.1cm)
MMP Weight: 22.5 lbs. (10.2 kg)
Shipping Dimensions (H x W x D): 22” x 15” x 12.5” (56.9cm x 38.1cm x 31.8cm)
Shipping Weight: 31.5 lbs. (14.3 kg)
Optional Accessories/Components:
•
•
•
•
•
•
ME-RC – Remote Control with LCD display; allows inverter (or connected accessory) to be
configured and monitored, and maintain the critical settings in nonvolatile memory.
ME-ARC – Advanced Remote Control with LCD display; has all the features of the ME-RC remote,
but also configures the advanced features of the inverter (or any connected accessory).
ME-BMK-NS – Battery monitor; determines Battery State of Charge (DC shunt not included).
ME-AGS-N – Automatic Generator Start Controller (network version); automatically starts/
stops generators.
BP-MMP – Metal Backplate; for mounting the Magnum inverter and MMP enclosure, and is UPS
shippable. See Figure A-3 in Appendix A for more specific information.
DC Breakers – Space for up to four E-Frame/back mounted (1” width) or eight Q-Frame/DIN
rail mounted (1/2” width) DC breakers.
Page 4
© 2010 Magnum Energy, Inc.
2.0 Introduction
2.2
MMP External Components
As shown in Figure 2-1, the main components found on the outside of the MMP enclosure are:
1
Top Plate - The MMP enclosure is shipped with the top plate installed and is used either
as an upper conduit plate or a safety plate. If you are not installing a Magnum inverter,
then use this plate to route the AC and DC wiring from the MMP enclosure to the inverter.
If installing a Magnum inverter, then remove this plate and store it in a safe place; where
it can be easily retrieved.
If the Magnum inverter is ever removed for service while the AC bypass is used, then
this plate must be installed to prevent accidental access to live electrical circuits inside
the MMP enclosure. Four #10 x 3/8”, T25 Torx drive screws hold the top plate to the
enclosure.
2
Remote Blank Plate - This plate is removed when an optional ME-RC or ME-ARC Remote
control is installed.
3
Conduit Knockouts - Knockouts to allow metal and PVC conduits. For dimensions and
sizes see Figure 3-2.
4
Knockout Panels - Eight 1/2” rectangular knockout panels provided to install additional
DC circuit breakers.
5
Front Cover - The front cover is removed to allow access to the internal components. Four
#10 x 3/8”, T25 Torx drive screws are used to hold the front cover to the enclosure.
1
2
3
4
5
Figure 2-1, MMP Outside Components
© 2010 Magnum Energy, Inc.
Page 5
2.0 Introduction
2.3
MMP Internal Components
The following components are found inside the MMP enclosure (refer to Figures 2-2 thru 2-5):
1
DC Negative to Ground Connection - A busbar connects the DC negative to the system
ground. This busbar can be removed if the primary DC negative to ground connection is
made elsewhere in the system (see Section 3.12).
2
Mounting Dimples (x4) - These dimples allow the optional ME-BMK-NS (Battery
Monitor Kit without DC shunt) to be installed. For more information on mounting the
battery monitor see Section A-2 in Appendix A.
3
Mounting Keyholes (x4) - Four keyholes for mounting the enclosure. See Figure 3-4
for size information on these keyholes.
4
Inverter AC Wiring Terminal - Terminal for connecting the inverter’s AC input and
output wires.
5
AC Breakers - This AC breaker assembly is pre-wired at the factory and consists of
the Inverter Bypass switch, and inverter input and output disconnect. These breakers
provide overcurrent protection and a way to disconnect the AC wiring inside the MMP
enclosure. These breakers can also provide overcurrent protection to the AC input source
and output load circuits if the minimum recommended AC wiring sizes are used.
6
External AC Wiring Terminal - Terminal for connecting the external AC source (utility/
generator) and the electrical panel that will be powered by the inverter.
7
AC Neutral to Ground Connection - A wire (green) connects the AC neutral to the
system ground. This green wire can be removed from the ground busbar if the primary
AC neutral to ground connection is made elsewhere in the system (see Section 3.11).
8
AC Ground Busbar - This busbar is connected to the MMP enclosure chassis and is used
to tie AC equipment grounds to a common point.
This busbar has dual hole sizes — three #14 to #1/0 AWG and six #14 to #6 AWG — with
screw type compression terminals (no ring lugs required).
9
Inverter’s DC Negative Connection 9A) Top of Inverter DC Negative Busbar; connects to Magnum inverter’s DC negative
terminal.
9B) Top of DC Shunt; connects to non-Magnum inverter’s DC negative terminal (the
Inverter DC Negative Busbar must be removed).
10
Inverter’s DC Positive Connection 10A) Top of Inverter DC Positive Busbar; connects to Magnum inverter’s DC positive
terminal.
10B) Top of Inverter DC Disconnect; connects to non-Magnum inverter’s DC positive
terminal (the Inverter DC Positive Busbar must be removed).
11
12
Page 6
DC Shunt - A 500 amp/50 mV shunt installed in the DC negative side that is used to
measure the amperage flowing between the battery and the inverter (and any DC loads
connected). This shunt is pre-installed so that a battery monitor may be easily connected
to display the current flow. See Section A-2 in Appendix A information on installing and
wiring the ME-BMK-NS battery monitor inside the MMP enclosure.
Battery Negative Connection - The bottom of the DC Shunt is the connection point to
the negative terminal of the battery bank.
© 2010 Magnum Energy, Inc.
2.0 Introduction
13
DC Ground Stud - This 5/16” stud is connected to the MMP enclosure chassis and is
provided as a connection point to the DC grounding electrode when the conductor is
larger than #1/0 AWG.
This 5/16” stud also connects to the DC Shunt through a busbar and serves as the DC
negative to ground connection point. If installing a PV-GFP device, this busbar must be
removed (see Section 3.12).
Note: For ground wires #1/0 AWG or smaller, use the DC Ground Busbar (Item 20).
14
15
16
17
18
19
DIN Rail Track - For installing up to eight 1/2” (12.7mm) wide, DIN rail mounted, QFrame type breakers. These breakers can be used for connecting DC loads or installing
a PV-GFP device.
Mounting Holes (x8) - For installing up to four 1” (25.4mm) wide, back mounted, EFrame type breakers. These breakers can be used for connecting DC loads or installing
a PV-GFP device.
Inverter DC Disconnect Breaker - This disconnect is a heavy-duty high amperage circuit
breaker specifically designed for the MMP enclosures. It provides an easy and convenient
way to isolate the inverter from the battery, and meets the NEC/CEC requirements for DC
overcurrent protection when used in accordance with the installation instructions in this
manual. The amperage rating depends on the MMP model (175 or 250 amps).
Battery Positive Connection - The bottom of the inverter’s DC disconnect is the
connection point to the positive terminal of the battery bank. The DC disconnect has a
front connected terminal with 3/8 - 16 captive nuts.
DC Positive Busbar - This busbar is connected to the battery bank positive through the
bottom of the inverter DC disconnect. This busbar is the battery positive common point
for connecting additional DC circuits, such as from the output of a charge controller or
connecting to DC load breakers.
This busbar is rated to handle 120 amps; and has dual hole sizes — two # 14 to #1/0
AWG and five #14 to #6 AWG — with screw type compression terminals (no ring lugs
required).
DC Negative Busbar -This busbar is connected to the battery bank negative through
the load side of the DC shunt. This busbar is the battery negative common point for
connecting additional DC circuits, such as from the DC negative output of a charge
controller or combining the negatives of DC load circuit breakers.
This busbar is rated to handle 120 amps; and has dual hole sizes — two # 14 to #1/0
AWG and five #14 to #6 AWG — with screw type compression terminals (no ring lugs
required).
20
DC Ground Busbar - This busbar is connected to the MMP enclosure chassis and is used
to tie DC equipment grounds to a common point. This terminal is also used to connect
the inverter/MMP enclosure system to the DC grounding electrode.
This busbar has dual hole sizes — two #14 to #1/0 AWG and three #14 to #6 AWG
— with screw type compression terminals (no ring lugs required).
If the DC grounding electrode conductor is greater than #1/0 AWG, use the DC Ground
Stud (Item 14) to connect the DC grounding electrode (i.e., ground rod).
© 2010 Magnum Energy, Inc.
Page 7
2.0 Introduction
NEGATIVE CONNECTION
9 A DC
(TO MAGNUM INVERTER)
DC NEGATIVE
TO GROUND 1
CONNECTION
POSITIVE CONNECTION
1 0 A DC
(TO MAGNUM INVERTER)
MOUNTING DIMPLES
(X4) FOR ME-BMK 2
NEGATIVE CONNECTION
9 B DC
(TO NON-MAGNUM INVERTER)
(ME-BMK NOT INCLUDED)
POSITIVE CONNECTION
1 0 B DC
(TO NON-MAGNUM INVERTER)
MOUNTING 3
KEYHOLES (X4)
1 1 DC SHUNT
INVERTER AC
WIRING TERMINAL 4
BATTERY NEGATIVE
1 2 CONNECTION
(INVERTER INPUT/OUTPUT)
(TO BATTERY BANK)
1 3 DC GROUND STUD
AC BREAKERS
(INVERTER BYPASS,
OUTPUT AND INPUT)
14
5
15
DIN RAIL TRACK
(FOR DIN RAIL MOUNTED
DC BREAKERS)
MOUNTING HOLES (X8)
(FOR BACK MOUNTED
DC BREAKERS)
1 6 DC INVERTER DISCONNECT
EXTERNAL AC
WIRING TERMINAL 6
BATTERY POSITIVE
1 7 CONNECTION
(FOR GRID/GENERATOR
AND AC LOADS)
(TO BATTERY BANK)
1 8 DC POSITIVE BUSBAR
AC NEUTRAL
TO GROUND 7
CONNECTION
1 9 DC NEGATIVE BUSBAR
AC GROUND 8
BUSBAR
2 0 DC GROUND BUSBAR
Figure 2-2, MMPxxx-30D Internal Components
INVERTER
BYPASS
INVERTER
OUTPUT
INVERTER
INPUT
Figure 2-3, MMPxxx-30D AC Breakers
Page 8
© 2010 Magnum Energy, Inc.
2.0 Introduction
NEGATIVE CONNECTION
9 A DC
(TO MAGNUM INVERTER)
DC NEGATIVE
TO GROUND
CONNECTION
1
POSITIVE CONNECTION
1 0 A DC
(TO MAGNUM INVERTER)
MOUNTING DIMPLES
(X4) FOR ME-BMK
2
NEGATIVE CONNECTION
9 B DC
(TO NON-MAGNUM INVERTER)
(ME-BMK NOT INCLUDED)
POSITIVE CONNECTION
1 0 B DC
(TO NON-MAGNUM INVERTER)
MOUNTING
KEYHOLES (X4)
3
INVERTER AC
WIRING TERMINAL
4
(INVERTER INPUT/OUTPUT)
1 1 DC SHUNT
BATTERY NEGATIVE
1 2 CONNECTION
(TO BATTERY BANK)
1 3 DC GROUND STUD
AC BREAKERS
(INVERTER BYPASS,
OUTPUT AND INPUT)
14
5
15
EXTERNAL AC
WIRING TERMINAL
(FOR GRID/GENERATOR
AND AC LOADS)
DIN RAIL TRACK
(FOR DIN RAIL MOUNTED
DC BREAKERS)
MOUNTING HOLES (X8)
(FOR BACK MOUNTED
DC BREAKERS)
1 6 DC INVERTER DISCONNECT
BATTERY POSITIVE
6
1 7 CONNECTION
(TO BATTERY BANK)
AC NEUTRAL
TO GROUND
CONNECTION
7
AC GROUND
BUSBAR
8
1 8 DC POSITIVE BUSBAR
1 9 DC NEGATIVE BUSBAR
2 0 DC GROUND BUSBAR
Figure 2-4, MMPxxx-60S Internal Components
INVERTER
BYPASS
INVERTER OUTPUT
(LEFT SIDE)
INVERTER INPUT
(RIGHT SIDE)
Figure 2-5, MMPxxx-60S AC Breakers
© 2010 Magnum Energy, Inc.
Page 9
3.0 Installation
3.0
Installation
Info: Installations should be performed by qualified personnel, such as a licensed
or certified electrician. It is the installer’s responsibility to determine which safety
codes apply and to ensure that all applicable installation requirements are followed.
Applicable installation codes vary depending on the specific location and application of
the installation.
CAUTION: Review the “Important Product Safety Information” on page 1 and the
“Important Battery Safety Instructions” on page 2 before any installation.
CAUTION: The MMP enclosure is heavy. Use proper lifting techniques during installation
to prevent personal injury.
The simplified system diagram shown in Figure 3-1 should be reviewed to assist you in planning
and designing your installation. This drawing is not intended to override or restrict any national
or local electrical codes; and should not be the determining factor as to whether the installation
is compliant, that is the responsibility of the electrician and the onsite inspector.
3.1 Preparation
Before installing the inverter, read the entire installation section to determine how you are going
to install your MMP enclosure. The more thorough you plan in the beginning, the better your
inverter needs will be met.
3.1.1 Unpacking and Inspection
Carefully remove the MMP enclosure from its shipping container and inspect all contents. Verify
the following items are included:
•
MMP enclosure
•
RJ14 Extension Cable
•
3/8-16 x 1” Bolt
•
Inverter Hood
•
6’ Network Cable
•
3/8” Split Lock Washer
•
Owner’s Manual
•
6’ Remote Cable
•
Four 8-32 x 1/2 Phillips drive, black colored screws taped to the back of the blank plate.
If items appear to be missing or damaged, contact your authorized Magnum Energy dealer or
Magnum Energy.
Save your proof-of-purchase as a record of your ownership; it will also be needed if the unit should
require in-warranty service.
3.1.2 Required Materials and Tools
The following material and tools may be required for installing this equipment:
Materials
•
Conduit, strain-reliefs, and appropriate fittings
•
1/4” mounting bolts and lock washers
•
Electrical tape
•
Wire ties
•
Conductors/cables for wiring
Tools
•
Miscellaneous screwdrivers
•
Insulated pliers
•
Wire cutters/strippers
•
Drill and drill bits
•
Pencil or marker
•
Multimeter
•
Level
•
1/2” wrench
•
Torque wrenches
•
Ratchet drives
Page 10
© 2010 Magnum Energy, Inc.
3.0 Installation
G E NE RATO R P O W E R
120/240 V A C OUTP UT
U TILITY P O W E R
120 /240V A C O UTP UT
M E - A G S -N
A u to G en S tart C o n tro ller
(M ag n u m O p tio n )
P V P ANE LS
e r at or
a c toi r G e n
F ul x C a p
AC
T RANS FE R
S W ITCH
M ag n u m In verter
(A ttach es o n
to p fo r a
seam less lo o k )
P V C HARG E
C O NTRO LLE R
M AIN P ANE L
M E -B M K -N S
B attery M o n ito r
(M ag n u m O p tio n ,
In stalls in sid e )
ON
ON
O FF
ON
O FF
ON
OF F
ON
O FF
ON
ON
O FF
O FF
ON
OF F
ON
O FF
ON
OF F
ON
O FF
ON
O FF
OF F
ON
OFF
MMP
ENCLOSURE
A C p o wer to in verter
S UB -P ANE L
ON
ON
ON
ON
O FF
O FF
O FF
O FF
63 A
63A
63 A
0. 5A
M E -R C o r M E- A R C
R em o te C o n tro ls
( M ag n u m O p tio n s )
S p ace fo r o p tio n al
D C circu it b reakers
an d P V -G F P
ON
30A
ON
3 0A
ON
ON
OF F
ON
OF F
ON
O FF
ON
OF F
ON
ON
O FF
ON
OF F
OF F
OF F
O FF
OF F
In verter p o wer
(o r p ass-th ru p o wer)
to Su b-p an el
B ATTE RY
B ANK
120
VA C
240
VA C
120
VA C
Figure 3-1, MMP Series Simplified Installation Diagram
© 2010 Magnum Energy, Inc.
Page 11
3.0 Installation
3.2 Location
Refer to the dimensional drawing in Figure 3-2 to determine an appropriate area to install the MMP
enclosure/inverter system. Install it only in a location that meets the following requirements:
Clean and Dry - The MMP/inverter system must be mounted indoors in a relatively cool, clean,
and dry environment.
Ventilation - If a Magnum inverter is installed on the MMP enclosure, these inverters pull in air
through the intake vents. In order for the inverter to provide full output power and avoid overtemperature fault conditions; do not cover or block the MMP enclosure ventilation openings, or
install it in an area with limited airflow. At the minimum, allow 3 inches of clearance to the left
and right sides of the MMP enclosure to provide adequate ventilation.
Close to the Battery Bank - The MMP enclosure/inverter system should be located as close to the
batteries as possible. This is to ensure the battery cable length is kept as short as possible. Long DC
wires tend to lose efficiency and reduce the overall performance of an inverter. However, the MMP
enclosure, the inverter, and any other equipment that can spark (or that corrosion could damage)
should not be installed in the same compartment/room as the batteries or mounted where it will
be exposed to gases produced by the batteries. These gases are corrosive and will damage this
equipment; also, if these gases are not ventilated and if allowed to collect, they could ignite and
cause an explosion. Consult your battery supplier for proper installation requirements.
Info: Consult your inverter owner’s manual to determine the proper sized inverterto-battery cables for the distance that is used. However, this cable must not be sized
any smaller than the minimum size requirement for the DC disconnect breaker in the
MMP enclosure. The MMP175 models require a minimum 00 (2/0) AWG cable, and the
MMP250 models require a minimum 0000 (4/0) AWG cable.
Safe - Keep any flammable/combustible material (e.g., paper, cloth, plastic, etc.) that may be
ignited by heat, sparks or flames at a minimum distance of 12 feet away from the MMP/inverter
system. Do not install the MMP/inverter system in any area that contains extremely flammable
liquids like gasoline or propane, or in locations that require ignition-protected devices. Sparks
from relays, circuit breakers, etc., could ignite the fumes or spills.
Accessible - Do not block access to the front of the MMP enclosure. Maintain at least a 36” (91 cm)
clear space in front to access the AC and DC wiring terminals and connections inside the MMP
enclosure, as they will need to be checked and tightened periodically.
3.3 Conduit Knockouts
The MMP enclosure comes standard with knockouts for 1/2”, 3/4”, 1”, 1 1/2”, and 2” conduits,
Figure 3-2 shows the location of these conduit knockouts. The 1/2”, 3/4”, and 1” knockouts are
for the PV array, DC loads, and other smaller input cables. Select the appropriate knockout that is
close to the terminal that the wire will connect to, or whichever one works for the way your field
wiring comes in. The 1 1/2” and 2” knockouts on the bottom of the MMP enclosure are used to
connect to the battery bank. If you are not installing a Magnum inverter, then use the 1 1/2” and
2” knockouts in the top plate to run inverter cables in conduit to that inverter.
Info: The knockouts can be easily removed by tapping the edge with a straight bladed
screwdriver and a hammer, then twist out with pliers; refer to Figure 3-3.
Think about whether you are going to use cable clamps or conduit and all the different wiring
required, before removing the appropriate knockouts and mounting the MMP enclosure, such as:
•
•
•
•
•
•
•
Wiring from the MMP enclosure to an AC sub-panel
Wire runs from the utility and/or a generator to the MMP enclosure
Battery cable wiring from the battery bank to the MMP enclosure
Additional wiring from any external DC source (PV, wind or hydro) to the MMP enclosure
Small signal wiring (battery sensors, battery monitoring, auto gen starting)
Attaching lightning arrestors
PV charge controller wiring
Page 12
© 2010 Magnum Energy, Inc.
3.0 Installation
TOP VIEW
( WITH TOP PLATE )
6
1
2
”
B
C
C
B
6 16 ”
D
11
7
12 8 ”
LEFT SIDE
VIEW
RIGHT SIDE
VIEW
FRONT VIEW
B
C
C
B
C
B
B
C
18 16 ”
1
C
C
C
A
A
A
A
6 16 ”
6 16 ”
11
CONDUIT KNOCKOUTS
(TOTAL):
A = ½ ” (x 4)
B = ½ ” and ¾ ” (x8 )
C = ¾ ” and 1” (x12)
D = 1 ½ ” and 2” (x2)
C
11
C
B
B
C
D
6 16 ”
11
BOTTOM VIEW
Figure 3-2, MMP Series Dimensions and Knockout Location/Sizes
© 2010 Magnum Energy, Inc.
Page 13
3.0 Installation
Figure 3-3, Removing Knockouts
3.4 Mounting
To meet regulatory requirements, the MMP enclosure must be mounted on a vertical surface (on
a wall) in an upright position, as shown in Figure 3-4. The DC breaker will not operate properly
unless in the vertical position.
Note the height you want to locate the MMP enclosure, and ensure you can access any controls
and wiring terminals. Refer to the physical dimensions as shown in Figure 3-2, or use the base
of the MMP as a template to mark your mounting screw locations. After marking the mounting
screw locations, firmly secure the MMP/inverter to an appropriate solid vertical surface using
appropriate mounting hardware.
This surface and the mounting hardware must also be capable of supporting at least three times
the combined weight of all the components (i.e., MMP enclosure, inverter, and any other accessory
mounted). When considering the strength of the support surface, remember the MMP enclosure
weighs 22.5 lbs. (10.2 kg), and the Magnum inverter can weigh up to 60 lbs. (27.2 kg).
If installing a Magnum inverter on the MMP enclosure, the inverter base can reach a temperature up
to 194°F (90°C); it is recommended that it should be mounted on a non-combustible surface*.
To meet regulatory requirements with a Magnum inverter mounted vertically, the included inverter
hood (PN-MP-HOOD) must be installed on the top to prevent the risk of fire from objects falling into
the inverter.
Info: Magnum provides a steel back plate (PN: BP-MMP) that has a suitable surface and
the required support for mounting the MMP enclosure and Magnum inverter together.
For information and dimensions on this backplate, see Figure A-3 in Appendix A.
Info: If mounting the MMP enclosure to wood (without a Magnum inverter), use at least
a #10 gauge sheet metal or wood screw. For concrete or hollow walls use a minimum
1/4 inch bolt and anchor.
* Non-combustible surface - A surface made of material that will not ignite, burn, support combustion, or
release flammable vapors when subjected to fire or heat as per the ASTM E136 standard. For the most
part, these are materials that are largely comprised of inorganic materials such as stone, steel, iron, brick,
tile concrete, slate, and glass. Common building materials such as gypsum board as well as any paint, wall
coverings, and certainly wood will not pass.
Page 14
© 2010 Magnum Energy, Inc.
3.0 Installation
3
16 4 ”
INVERTER
HOOD
INVERTER
16 ”
HOODand
(included
required
for UL1741)
BP-MMP
BP-MMP
BACKPLATE
ACKPLATE,
MINI
INI
13 16 ”
1
M
MAGNUM
AGNUM
IINVERTER
NVERTER
34 16 ”
3
MMPMMP
SERIES
EENCLOSURE
NCLOSURE
18 16 ”
1
11 ”
KKEYHOLE
EYHOLE
DDETAIL
4)
ETAIL ((XX4)
0.465"
0.409"
0.2"
0.28 Ø
0.438"
3
11 4 ”
5
12 8 ”
KKEYHOLES
WITH
EYHOLES((XX4)
4) WITH
MMOUNTING
S
CREWS
OUNTING SCREWS
Figure 3-4, Keyhole Locations for Mounting
© 2010 Magnum Energy, Inc.
Page 15
3.0 Installation
3.5 Wiring the MMP Enclosure - General Requirements
This section also describes the requirements and recommendations for the electrical wiring to the
MMP enclosure. Read all instructions before wiring the MMP enclosure.
All wiring should meet all local codes and standards and be performed by qualified
personnel such as a licensed electrician.
The NEC (National Electric Code, ANSI/NFPA 70) for the United States and the CEC (Canadian
Electrical Code) for Canada provide the standards for safely wiring residential and commercial
installations. The NEC/CEC lists the requirement for wire sizes, overcurrent protection and
installation methods and requirements.
The MMP enclosure/Inverter systems involve power from multiple sources (inverter, generator,
utility, batteries, solar arrays, etc.) which make the wiring more hazardous and challenging.
WARNING: The AC neutral and DC negative are bonded to ground in this enclosure.
If the AC or DC circuits are already bonded to ground elsewhere in your system, you
must remove the DC and/or AC bonding inside this enclosure. Refer to Section 3.11
and 3.12 to remove the AC and/or DC ground bond connection.
WARNING: Ensure all sources of DC power (i.e., batteries, solar, wind, or hydro) and
AC power (utility power or AC generator) are de-energized (i.e., breakers opened,
fuses removed) before proceeding - to prevent accidental shock.
3.5.1
Disconnect Switch and Overcurrent Protection
For residential and commercial electrical systems, the NEC/CEC requires a disconnect switch and
overcurrent protection on all ungrounded conductors in the AC side as well as the DC side. The
MMP enclosure provides both AC and DC circuit breakers that are used as the disconnect switch.
These circuit breakers can also be used as the overcurrent protection device when the ampacity
of the wire, its insulating material, voltage, and temperature rating are correctly sized to the DC
circuit breakers in your MMP enclosure. Refer to the appropriate installation section (AC Wiring or
DC Wiring) to determine the minimum recommended wire size required.
3.5.2
Wiring Requirements
The AC and DC wires into and out of the MMP enclosure must be protected as required by code.
This can be done by using jacketed wires or by feeding the wires through conduit.
Info: If using a Magnum inverter, and the AC wires are individual conductors (i.e., not
jacketed), the strain reliefs on the inverter can be replaced with 3/4” grommets.
• Use proper clamps, or other approved methods for securing the cable/conduit to the enclosure.
• Do not mix AC and DC wiring in the same conduit. The MMP enclosure is specifically approved/
designed for both AC and DC wiring. However, where DC wiring must cross AC or vice-versa,
try to make the wires at the crossing point 90° to one another.
• Use only copper wires with a minimum rating of 150V, 75°C if only 120VAC power is being
used; or with a minimum rating of 300V, 75°C if 120/240VAC power is being used.
• In a system where one conductor is grounded the wire colors on the DC side and AC side are the
same. The insulation on all grounded conductors (DC negative/AC neutral) must be white, gray,
or any color except green if marked with white at each termination (marking only allowed on 6
AWG or larger conductors). The equipment grounding conductors must be bare (no insulation),
or have green or green with yellow-striped insulation or identification. The hot-ungrounded
conductor (DC positive/AC hot) is usually red or black.
• Terminals containing more than one conductor must be listed for multiple conductors.
• The connectors or terminals used on flexible, fine-stranded conductors must be specifically
marked or labeled for use with fine-stranded conductors.
• The MMP enclosure includes wires (along with communication cables) with insulation rated
for at least 300 volts to allow 120/240 VAC inverters to be installed. If installing a 120/240
VAC inverter, the installer must also provide wires (both power and communication) with the
insulation rated for at least 300 volts.
Page 16
© 2010 Magnum Energy, Inc.
3.0 Installation
3.5.3
Wire Routing
Before connecting any wires, determine all wire routes to and from the MMP enclosure/inverter.
Typical routing scenarios are:
•
•
•
•
•
•
•
•
AC input wiring from the main AC panel or from a generator to the MMP enclosure
AC input and output from the MMP enclosure to the inverter
DC wiring from the batteries to the MMP enclosure
DC wiring from the inverter to the MMP enclosure
AC output wiring from the MMP enclosure to the AC sub-panel or to dedicated circuits
Battery Temperature Sensor cable from the inverter to the batteries
Remote Control cable (optional) to the inverter through the MMP enclosure
Ground wiring to and from the MMP enclosure
3.6 Torque Requirements
Follow the specific torque recommendations below to ensure your fasteners are tightened sufficiently.
To ensure your connections are correct, you should use an accurate, quality torque wrench. It is
highly recommended to go back over all fasteners and re-torque after 5 days and every 6 months
thereafter.
CAUTION: AC and DC power/wire connections that are under-torqued could become
loose and result in a fire hazard. On the other hand, over tightening a bolt could cause
the fastener to be snapped off.
Table 3-1, Torque Values for Busbars
Torque values for the ground busbars, DC negative busbar, and DC positive busbar
(these busbars have different torque values for the small and large screws)
Wire Size
Busbar Screw Size Torque Values
10-32 (Small Screw)
5/16-24 (Large Screw)
#14 to #10 AWG
15 in. lbs. (1.7 N-m)
35 in. lbs. (4.0 N-m)
#8 AWG
20 in. lbs. (2.3 N-m)
40 in. lbs. (4.5 N-m)
#6 AWG
25 in. lbs. (2.8 N-m)
45 in. lbs. (5.1 N-m)
#4 AWG
NA
45 in. lbs. (5.1 N-m)
#3 to 1/0 AWG
NA
50 in. lbs. (5.6 N-m)
Table 3-2, Torque Values for the DC Shunt and DC Disconnect Breaker
3/8-16 Bolt Torque Value
10 to 12 ft. lbs.
(13.6 to 16.3 N-m)
Table 3-3, Torque Values for the AC Terminal Blocks
Wire Size
Slotted M5 screw Torque Values
#14 to #6 AWG
16.0 in. lbs. maximum
(2.0 N-m maximum)
3.7 Electrical System Wiring Diagrams
Diagrams of the AC and DC wiring for the MMP Series enclosure are shown in Figures 3-5 and 36, and are provided to assist you or your system installer. Due to the variety of applications and
differences in local and national electrical codes, these wiring diagrams should be used as general
guidelines only. They are not intended to override or restrict any national or local electrical codes;
and, should not be the determining factor as to whether the installation is compliant, that is the
responsibility of the electrician and the onsite inspector.
© 2010 Magnum Energy, Inc.
Page 17
3.0 Installation
MA GN U M EN ER GY
I N VER T ER /C H A R GER
P V C H A R GE
C ON T R OL L ER
M M P X X X -30 D
SYSTEM
W IR IN G
S C H E M A T IC
P V P A N EL S
H2 H1 N
O O O
AC
W IR IN G
H2 H1 N
I I I
B
B
B
B
PV
PV PV
PV
PV-GFP
63A
ON
ON
O FF
O FF
63A 0.5A
I NV E RTE R D C
D IS CO NNE CT
N EUTRAL G ROUND
C ONNECTION1
E X TE RNAL A C
I NP UT / O UTP UT
T E RMINAL B LO CK
63A
ON
O FF
D C S HUNT
I NV E RTE R
O UTP UT
B RE AKE R
ON
O FF
DC
N EG ATI VE
B US BAR
I NV E RTE R
I NP UT
B RE AKE R
AND
G ROU ND
B US BAR
I NV E RTE R
B Y P AS S
B RE AKE R
PV O UTP UT
N ote 1: R em ove
the ‘N E UTRA L –
G RO UND
connection’ if the
M ain AC Source
has a N eutral to
Ground
connection .
I NV E RTE R A C
I NP UT / O UTP UT
T E RMINAL B LO CK
PV + I NPU T
MMP
E N C L OSU R E
DC
G RO UND
S TUD
N EGATIVE - GROUND
C ONNECTION2
H OT H OT
N EU GN D
2
1
IN
IN
IN
< 1/0
AW G
≥ 1/0
AW G
B
B
ON
30A
ON
ON
OF F
OFF
ON
OF F
OFF
OF F
OF F
ON
ON
OF F
ON
OF F
ON
ON
OFF
ON
OFF
OF F
ON
OF F
OF F
ON
OF F
ON
240V
S YST EM G R OU N D
OF F
ON
OF F
OF F
ON
ON
OFF
ON
ON
OF F
OF F
ON
OF F
OF F
ON
ON
3 0A
OF F
ON
ON
OF F
120V
H OT H OT
N EU GN D
2
1
OU T OU T OU T
D C P O S ITIV E
B US BAR
O P TIO NAL D C
B RE AKE RS /D IS CO NNE CTS
[SPA C ES A VA IL A B L E :
120V
A C S U B - P A N EL
(I N VER T ER L OA D S)
N ote 2: D C – G RO UND
busbar show n installed .
T his busbar m ust be
rem oved w hen a PV-GF P is
installed to prevent m ultiple
D C to ground connections.
A C M A IN P A N EL
( A C S OU R C E)
B A T T ER Y B A N K
(D C S OU R C E)
DC
W IR IN G
D IN R A IL M O U N T ( X 8 ) /
B A C K- M O U N T ( X 4) ]
Figure 3-5, MMPxxx-30D System Wiring Diagram
Page 18
© 2010 Magnum Energy, Inc.
3.0 Installation
MA GN U M EN ER GY
I N VER T ER /C H A R GER
P V C H A R GE
C ON T R OL L ER
M M P X X X -60 S
SYSTEM
W IR IN G
S C H E M A T IC
P V P A N EL S
G RO UND
B US BAR
I NV E RTE R
I NP UT
B RE AKE R
INV E RTE R
O UTP UT
B RE AKE R
N EUTRAL G ROUND
C ONNECTION1
E X TE RNAL A C
I NP UT / O UTP UT
T E RMINAL B LO CK
63A
P
V
ON
O FF
63A
PV
ON
ON
O FF
O FF
6 3 A 0 .5 A
D C S HUNT
AND
ON
O FF
P
V
PV
PV PV
DC
N EG ATI VE
B US BAR
INV E RTE R
B Y P AS S
B RE AKE R
PV O UTP UT
N ote 1: R em ove the
‘N E UTRA L – G RO UND
connection’ if the
M ain AC Source has
a N eutral to Ground
connection .
I NV E RTE R A C
I NP UT / O UTP UT
T E RMINAL B LO CK
B
I NV E RTE R D C
D IS CO NNE CT
MMP
E N C L OSU R E
B
B
PV-G FP
AC
W IR IN G
B
PV + I NP UT
H2 H1 N
I I I
H2 H1 N
O O O
DC
G RO UND
S TUD
D C P O S ITIV E
B US BAR
N EGATIVE - G ROUND
C ONNECTION2
GN D
N EU
IN
ON
ON
OF F
ON
ON
OF F
OFF
ON
ON
OF F
ON
A C M A IN P A N EL
(A C S o u rce )
ON
OF F
ON
OF F
ON
OFF
ON
OF F
ON
O FF
OFF
ON
OF F
OF F
O FF
OF F
ON
ON
ON
OF F
ON
OF F
ON
OF F
OFF
≥ 1/0
AW G
B
B
B
S YST EM G R OU N D
N ote 2: D C – G RO UND
busbar show n installed .
T his busbar m ust be
rem oved w hen a PV-GF P is
installed to prevent m ultiple
D C to ground connections.
O P TIO NAL D C
B RE AKE RS /D IS CO NNE CTS
[ SPA C ES A VA IL A B L E :
120V
A C S U B - P A N EL
(I N VER T ER L OA D S)
< 1/0
AW G
OF F
OF F
ON
OF F
ON
ON
OF F
30 A
OFF
120V
N EU
OU T
GN D
ON
OF F
30A
A C S U B -P A N EL
( In verter L o ad s )
H OT
1
OU T
ON
H OT
1
IN
A C M A IN P A N EL
( A C S OU R C E)
B A T T ER Y B A N K
(D C S OU R C E)
D IN R A IL M O U N T ( X 8) /
B A C K-M O U N T ( X 4) ]
DC
W IR IN G
Figure 3-6, MMPxxx-60S System Wiring Diagram
© 2010 Magnum Energy, Inc.
Page 19
3.0 Installation
3.8 DC Wiring
This section describes the DC wiring inside the MMP enclosure to the inverter and Battery Bank.
Figure 3-7 shows the connection points for all battery bank and inverter (DC side) wiring inside
the MMP enclosure. If installing optional DC breakers, see Section A-4 in Appendix A.
The DC wiring for the MMP enclosure is further detailed in Figure 3-10 for systems using a Magnum
Energy inverter, and in Figure 3-11 for systems not using a Magnum inverter. These detailed
diagrams should be reviewed to assist in wiring the DC circuits, however, they are not intended
to override or restrict any national or local electrical codes. These drawings should not be the
determining factor as to whether the installation is compliant, that is the responsibility of the
electrician and the onsite inspector.
3.8.1
DC Wiring Guidelines
WARNING: During normal operation, the terminals, busbars, and electrical components
inside the MMP enclosure may be energized - DO NOT TOUCH. Disconnect all power
sources before removing the cover.
WARNING: Even though DC voltage is “low voltage”, significant hazards may be
present, particularly from short circuits of the battery system.
CAUTION: Before wiring the DC cables, review the safety information at the beginning
of this manual and the following information to ensure a safe and long-lived system.
CAUTION: If you are using fine-stranded DC cables, the crimp or compression lug
used must be specifically marked or labeled for use with fine-stranded conductors.
Failure to use the proper terminal may cause the connection to heat-up, and may
eventually fail or become a fire hazard.
CAUTION: DO NOT connect the battery cables to the inverter until all wiring is complete
and the correct DC voltage and polarity have been verified.
•
•
•
•
•
•
•
•
•
When the inverter is installed in a Photovoltaic System, the NEC requires that the DC circuit
conductors and overcurrent devices to the inverter be sized to carry not less than 125% of
the inverter’s maximum current rating.
The DC positive and negative cables from the battery bank should be tied together with wire
ties or electrical tape approximately every 6 inches. This helps improve the surge capability
and reduces the effects of inductance, which improves the inverter waveform and reduces the
wear of the inverter’s filter capacitors.
Crimped and sealed copper compression lugs with a 3/8” hole should be used to connect the
battery cables to the DC Disconnect breaker and the DC Shunt inside the MMP enclosure.
The battery bank voltage MUST match the DC voltage required by the inverter (i.e., 24-volt
battery bank for a 24-volt inverter), or the inverter may be damaged.
The DC cables must be of a type listed for use in conduit (RHW or THW).
To ensure the maximum performance from the inverter, all connections from the battery
bank to the inverter through the MMP enclosure should be minimized, the exception is the DC
circuit breaker in the positive line and the DC shunt in the negative line. Any other additional
connection will contribute to additional voltage drops and may loosen during use.
All wiring to the inverter and battery terminals should be checked periodically (once a month)
for proper tightness. Refer to the torque requirements in Tables 3-1 to 3-3.
After making the battery connections and ensuring they are properly tightened, cover the
outside of the connection with petroleum jelly or an antioxidant grease/spray. Do not put
jelly/anti-corrosion grease between the terminal and the battery cable.
Ensure the color code for the DC cables/wires are correct: RED for positive (+); WHITE for
negative (-); and GREEN, GREEN/YELLOW, or bare for DC equipment grounds.
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© 2010 Magnum Energy, Inc.
3.0 Installation
3.8.2
DC Wiring Connection Points
Figure 3-7 shows the connection points for the DC wiring inside the MMP enclosure.
DC1A
D CINVERTER
N egative
connection
DC NEGATIVEto
CInverter
ONNECTION
DC2A
BUSBARS
B
us ba rs
usWITH
e
FORfor
USE
w ith
MMAGNUM
a gnum
D CINVERTER
P ositive
connection
DC POSITIVE
to
Inverter
CONNECTION
INVERTERS
Inv e rte r
DC1B
DC2B
BATTERY
BANK
D
C N egative
NEGATIVE
connection
C
toONNECTION
B attery
DC3
BATTERY
BANK
D
C P ositive
POSITIVE
connection
CONNECTION
to
B attery
To
DC
DC
GROUNDING
Grounding
E
LECTRODE
E lectrode
ONNECTION
CConductor
DC4
DC5A
DC5B
To Inverter’s
QUIPMENT
D DC
C EEquipm
ent
GROUNDING
Grounding
ONNECTION
CConductor
DC6
Figure 3-7, DC Wiring Connection Points
DC1
Inverter DC Negative Connection
DC1A (Magnum inverter) - Top of DC negative busbar connects to Magnum inverter’s DC
negative terminal.
DC1B (Non-Magnum inverter) - Remove the DC negative busbar and connect the inverter’s
(non-Magnum) DC negative terminal to the top of DC shunt.
DC2
Inverter DC Positive Connection
DC2A (Magnum inverter) - Top of DC positive busbar connects to Magnum inverter’s DC
positive terminal.
DC2B (Non-Magnum inverter) - Remove the DC positive busbar and connect the inverter’s
(non-Magnum) DC positive terminal to the top of the inverter DC breaker.
DC3
Battery Bank Negative Connection - Bottom of DC shunt connects to the battery
bank’s negative terminal.
DC4
Battery Bank Positive Connection - Bottom of the inverter’s DC disconnect breaker
connects to the battery bank’s positive terminal.
DC5
DC Grounding Electrode Connection - The connection point for the MMP/inverter
system to the DC grounding electrode. Use DC5A for greater than #1/0 AWG wires and
DC5B for #6 to #1/0 AWG wires.
DC6
DC Equipment Grounding Connection - This busbar serves as the common DC
equipment ground point for all DC equipment used in the MMP/inverter system.
© 2010 Magnum Energy, Inc.
Page 21
3.0 Installation
M agnum Inverter
front view
B TS
B TS
Inv e rte r’s D C N e ga tiv e B us ba r
Inv e rte r’s D C P os itiv e B us ba r
Inv e rte r’s E quipm e nt G round W ire
B a tte ry Te m p S e ns or C a ble*
* If the v olta ge ins ide the e nc los ure is
gre a te r tha n 1 5 0 v olts (i .e ., 1 2 0/2 4 0V A C
s ourc e/inv e rte r), us e the prov ide d
e x te ns ion c a ble (w ith 3 0 0 v olt ra te d
ins ula tion ) to c onne c t the B TS c a ble
B a tte ry B a nk ’s E quipm e nt G round W ire
B a tte ry B a nk ’s N e ga tiv e C a ble
B a tte ry B a nk ’s P os itiv e C a ble
D C S y s te m G rounding point
[E le c trode C onduc tor
(i .e ., ground rod )]
Battery Bank
Figure 3-8, DC Wiring with Magnum Inverter
Page 22
© 2010 Magnum Energy, Inc.
3.0 Installation
INVERTER/CHARGER
DC
INPUT
Inv e rte r’s D C P os itiv e C a ble
Inv e rte r’s D C N e ga tiv e C a ble
Inv e rte r’s E quipm e nt G round W ire
B a tte ry B a nk ’s E quipm e nt G round W ire
B a tte ry B a nk ’s N e ga tiv e C a ble
B a tte ry B a nk ’s P os itiv e C a ble
D C S y s te m G rounding point
[E le c trode C onduc tor
(i .e ., ground rod )]
Battery Bank
Figure 3-9, DC Wiring with non-Magnum Inverter
© 2010 Magnum Energy, Inc.
Page 23
3.0 Installation
3.8.3
Inverter DC Overcurrent Protection and DC Disconnect
In a battery based inverter system, the NEC/CEC assumes that each ungrounded conductor is
connected to some source that supplies currents in excess of the ampacity rating of the conductor
and could potentially damage that conductor under fault conditions. Because of this, the NEC/CEC
requires that all ungrounded conductors in the inverter’s DC system be protected by an overcurrent
device, this can be either a circuit breaker or fuse. These breakers or fuses are not intended to
protect equipment from damage, but protect the conductor/wire from overheating which may
potentiality cause a fire. This means the overcurrent device is required to open before the conductor
reaches its maximum current carrying capability, thereby preventing a fire.
Info: Circuit breakers or fuses that are used on the DC side must be UL listed and DC
rated for the application.
The NEC also requires the inverter system to have a DC disconnect switch to allow the inverter
service providers to isolate the inverter from the battery. The disconnect must be either a DC
rated circuit breaker or switch.
Depending on your model, the MMP enclosure is provided with either a 175 amp or 250 amp
UL listed, high interruption capacity DC rated circuit breaker. These breakers are designed to
interrupt the tremendous amount of current a battery can deliver when short-circuited. They are
also specifically designed to have a long enough time delay to prevent the breaker from tripping,
as the inverter requires high current levels when powering heavy loads.
When properly located and used with the minimum DC wire size shown in Table 3-4, these circuit
breakers can provide the inverter system with both the DC overcurrent protection device and a
safety disconnect switch.
3.8.4
Inverter and Battery Bank Wire Sizing
In a low voltage/high amperage system, it is important to use the correct DC wire to achieve
maximum efficiency from the system and reduce fire hazards associated with overheating. Always
keep your wire runs as short as practical to help prevent low voltage shutdowns and keep the DC
breaker from nuisance tripping, because of increased current draw.
The size of the DC cables must be correctly sized according to the inverter’s DC current requirements,
DC breaker size, and the minimum voltage drop to the battery bank. If the DC circuit breaker
provided in the MMP enclosure is being used as the inverter’s DC overcurrent protection device,
the cable size must not be less than the minimum DC wire size shown in Table 3-4.
Use Table 3-4 to select the minimum DC wire size based on your MMP model. These recommendations
may not meet the inverter’s continuous current requirements1 or electrical code requirements.
Table 3-4, Recommended DC Wire to MMP enclosure
MMP Model
DC Circuit
Breaker
Minimum DC Wire
Size (rating)2
DC Equipment
Grounding Wire Size3
MMP175-30D
175 amps
#2/0 AWG (195 amps)
#6 AWG
MMP175-60S
175 amps
#2/0 AWG (195 amps)
#6 AWG
MMP250-30D
250 amps
#4/0 AWG (260 amps)
#4 AWG
MMP250-60S
250 amps
#4/0 AWG (260 amps)
#4 AWG
WARNING: If you use a battery or inverter cable smaller than the recommended
minimum DC wire size for your MMP model (as shown in Table 3-4), you must install a
fuse/circuit breaker compatible with this smaller cable to protect against a potential fire.
1
Note 1 - Refer to your inverter’s owner’s manual to determine the minimum DC wire requirements.
Note 2 - Wire must be copper with a minimum rating of 300V, 75°C at an ambient temperature of 30°C.
Note 3 - See Section 3.10 more information on the Equipment Grounding wire size.
Page 24
© 2010 Magnum Energy, Inc.
3.0 Installation
3.8.5
DC Hardware Connections
Do not put anything between the DC cable lug and the DC terminals (i.e., on the DC circuit breaker,
DC shunt, batteries, and inverter/busbars). Ensure the hardware used to hold these connections is
stacked correctly. Incorrectly installed hardware causes a high resistance connection which could
lead to poor inverter performance, and may melt the cable and terminal connections.
Follow Figures 3-10 and 3-11 on how to connect the DC cables and stack the hardware correctly.
Info: After making the battery connections and ensuring they are properly torqued,
cover the outside of the connection with petroleum jelly or an antioxidant grease/spray.
Do not put jelly/anti-corrosion grease between the terminal and the battery cable.
Busbar Hardware Stack-up:
1
INVERTER DC NEGATIVE AND
POSITIVE CONNECTIONS
1 Inverter DC terminal
busbar
2 Copper
[(-) to shunt, (+) to DC breaker]
3 5/16-18 Nut (Flange or Kep)
DO NOT Place anything between
the Inverter DC terminal and the
copper busbar.
2
3
BATTERY NEGATIVE CONNECTION
1
Bottom of Shunt
hardware stack-up:
1 DC Shunt
2 DC Neg. to Ground Busbar
3 Negative (-) Battery Cable Lug
4 Brass Flat washer
2
4 5 6
3
5 Brass Split-lock washer
6 Brass Hex Bolt (3/8-16)
DO NOT place anything between
the DC shunt and the busbar
or between the busbar and the
negative battery cable lug.
BATTERY POSITIVE CONNECTION
1
Bottom of DC Breaker
hardware stack-up:
1 DC Breaker Terminal
2
2 Positive (+) Battery Cable Lug
3 Split-lock washer
3
4
4 Hex Bolt (3/8-16)
DO NOT place anything between
the DC breaker terminal and the
positive battery cable lug.
Figure 3-10, DC Connections - with Magnum Inverter Installed
© 2010 Magnum Energy, Inc.
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3.0 Installation
INVERTERD CDCNNegEGATIVE
In verter
ative C
C ONNECTION
o n n ectio n
1
2
4 5
3
Top of Shunt
hardware stack-up:
1 DC Shunt
2 Negative (-) Inverter Cable Lug
6
3 DC Negative (-) Busbar Cable
4 Brass Flat washer
5 Brass Split-lock washer
6 Brass Hex Bolt (3/8-16)
DO NOT place anything between
the DC shunt and the negative
inverter cable lug.
INVERTER
CONNECTION
In verter
D CDCP P
o OSITIVE
sitive C
o n n ectio n
3
4
Top of DC Breaker
hardware stack-up:
1 DC Breaker Terminal
2 Positive (+) Inverter Cable Lug
3 Split-lock washer
4 Hex Bolt (3/8-16)
DO NOT place anything between
the DC breaker terminal and the
positive inverter cable lug.
2
1
BATTERY
NEGATIVE
B attery
N eg
ative CCoONNECTION
n n ectio n
1
Bottom of Shunt
hardware stack-up:
1 DC Shunt
2 DC Neg. to Ground Busbar
3 Negative (-) Battery Cable Lug
4 Brass Flat washer
5 Brass Split-lock washer
2
4 5 6
3
6 Brass Hex Bolt (3/8-16)
DO NOT place anything between
the DC shunt and the busbar
or between the busbar and the
negative battery cable lug.
BATTERYP oPsitive
OSITIVE C
CoONNECTION
B attery
n n ectio n
1
Bottom of DC Breaker
hardware stack-up:
1 DC Breaker Terminal
2
2 Positive (+) Battery Cable Lug
3 Split-lock washer
3
4
4 Hex Bolt (3/8-16)
DO NOT place anything between
the DC breaker terminal and the
positive battery cable lug.
Figure 3-11, DC Connections - without Magnum Inverter Installed
Page 26
© 2010 Magnum Energy, Inc.
3.0 Installation
3.8.6
Wiring the Battery Bank
Depending upon the voltage of the batteries you use in the installation (6 or 12 VDC), the batteries
must be wired in series, parallel, or series-parallel to provide the correct voltage. The interconnecting
DC wires should be sized and rated exactly the same as those that are used between the battery
bank and the inverter.
Place the batteries as close as practical to the MMP enclosure/inverter system, preferably in an
insulated and ventilated enclosure. Allow adequate space above the batteries to access the terminals
and vent caps (as applicable). Also allow at least 1” of space between the batteries to provide good
air flow. DO NOT mount the batteries directly under the MMP enclosure/inverter system.
Info: To ensure the best performance from your MMP enclosure/inverter system, batteries
should be of the same size, type, rating, and age. Do not use old or untested batteries.
3.8.7
Wiring the MMP Enclosure to the Battery Bank/Inverter
WARNING: Ensure that all AC and DC breakers are switched OFF before connecting
or disconnecting the battery cables, and that all sources of power (both AC and DC)
are disconnected from the inverter.
WARNING: Lethal currents will be present if the positive and negative cables attached
to the battery bank touch each other. During the installation and wiring process, ensure
the cable ends are insulated or covered to prevent touching/shorting the cables.
CAUTION: DO NOT connect the DC wires to the battery bank until: 1) all DC, AC, and
accessory wiring are completed, 2) the correct DC and AC overcurrent protection have
been installed and, 3) the correct DC voltage and polarity have been verified.
CAUTION: The Magnum inverter is NOT reverse polarity protected, if this happens
the inverter will be damaged and will not be covered under warranty. Before making
the final DC connection from the batteries up to the inverter, verify the correct battery
voltage and polarity by using a voltmeter. If the positive (+) terminal of the battery is
connected to the negative (–) terminal of the inverter and vice versa, severe damage
will result. Ensure the cables are color-coded to avoid polarity confusion.
This section describes how to make DC connections between the inverter/charger and the MMP
enclosure (using a Magnum inverter or not), between the MMP enclosure to the batteries (using
battery cables provided by the installer - see Table 3-4).
1a. Using Magnum Inverter - Place the Magnum Inverter onto the top of the MMP enclosure,
ensuring the inverter’s DC terminals fit through the holes in the pre-installed DC positive and
negative busbars within the MMP enclosure.
1b. Not using Magnum Inverter - Route the DC cables from the inverter and connect them inside
the MMP enclosure; negative cable (-) to the top side of the DC shunt, positive cable (+) to the
top side of the DC breaker. Be careful to observe proper polarity.
2. Route the DC cables from the battery bank — with the cables not connected to the battery — and
connect them to the MMP enclosure; negative (-) to the bottom side of the DC shunt, positive (+)
to the bottom side of the DC breaker. Be careful to observe proper polarity.
3. Ensure the DC wire connections (on the batteries, inverter, DC circuit breaker and DC shunt)
are flush on the surface of the DC terminals and the hardware used to hold these connections are
stacked correctly (see Figures 3-11 and 3-12); and then securely tighten these DC connections.
Only after the entire installation is complete and all connections are verified, should the DC circuit
breaker be closed to provide power to the inverter.
4. Route an appropriately sized DC grounding wire (green or bare wire) from the inverter’s DC
equipment ground terminal and from the battery bank enclosure to the DC ground busbar in the
MMP enclosure. Refer to Section 3.10 for grounding information and sizing the DC ground wires.
© 2010 Magnum Energy, Inc.
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3.0 Installation
3.9
AC Wiring
This section provides information on the AC wiring inside the MMP enclosure to/from the inverter,
from the incoming AC source and to the outgoing AC distribution panel (i.e., inverter sub-panel).
3.9.1
AC Wiring Guidelines
CAUTION: Before installing any AC wiring, review the safety information at the
beginning of this manual and below to ensure a safe and long-lived system:
• Read all instructions and cautionary markings located at the beginning of this manual
and in the pre-installation section, before installing the inverter and batteries.
• AC wiring must be no less than #10 AWG (5.3 mm2) gauge copper wire and be
approved for residential wiring.
• DO NOT connect the Magnum inverter’s output to an AC power source. This could
cause severe damage to the inverter and is not covered under warranty.
WARNING: To reduce the risk of fire, do not connect a 120VAC only inverter to both
busbars in an AC load center (circuit breaker panel) having multi-wire branch circuits
connected. Every circuit connected to a 120VAC panel must have its own neutral;
otherwise, currents on shared neutrals will add rather than subtract, overloading the
neutral conductor.
3.9.2
AC Connections
Use either Figure 3-12 (for MMPxxx-30D models) or Figure 3-13 (for MMPxxx-60S models) to view
the AC connection points inside the MMP enclosure.
3.9.2.1
AC Input/Output Connections
The MMP enclosure provides two AC terminal blocks that allow the AC input and output wiring to
be easily and permanently wired. These terminal blocks allow a service/distribution panel (main
panel) to be wired to the inverter’s input; and a dedicated inverter panel (sub-panel)1 to be wired
between the inverter’s output wiring and the AC loads.
Depending on your MMP model, it will either have two six-pole AC terminals (Figure 2-2, Items
4 and 6), or two four-pole AC terminals (Figure 2-4, Items 4 and 6). The six-pole terminals are
provided on the MMPxxx-30D models to allow 120/240 VAC inverters — up to 30 AC amps per leg
pass-thru capability— to be connected. The four-pole terminals are provided on the MMPxxx-60S
models to allow 120VAC inverters — up to 60 AC amps pass-thru capability — to be connected.
The upper AC terminal block - INVERTER AC TERMINAL BLOCK - provides the connection points for
the inverter’s input and output Hot and Neutral connection points. The lower AC terminal block EXTERNAL AC TERMINAL BLOCK - provides the Hot and Neutral connection points for the incoming
utility/AC generator input and to the inverter AC sub-panel (if needed)1.
Info: The neutrals on the INVERTER AC TERMINAL BLOCK are NOT connected together.
You must provide both an inverter input and output neutral connection to the inverter’s AC
terminal unless the inverter has the input and output neutrals connected together,
Each connection on the AC terminal block is rated to accept one #14 to #6 AWG (2.1 to 13.3 mm2) CU
stranded wire; or, two #12 AWG (3.3 mm2) CU stranded wires. Each connection uses a M3.5, slotted
screw and the maximum tightening torque is 16 lbf-in (1.8 N-m).
3.9.2.2
AC Ground Connections
The MMP enclosure comes with an AC ground busbar (Item 8, in Figure 2-2 or 2-4) to allow the
AC grounds to be connected to a common point. This busbar has three #14 to #1/0 AWG and six
#14 to #6 AWG screw type compression terminals. See Table 3-1 for torque requirements.
CAUTION: A neutral to ground connection is provided in the MMP enclosure. If this
neutral-ground connection is provided elsewhere in the AC system, this connection must
be disconnected. See Section 3-11 for information to disconnect this connection.
Note 1 - MS2012/MS2000 (-15B and -20B) breaker models do not require a dedicated inverter sub-panel.
Page 28
© 2010 Magnum Energy, Inc.
3.0 Installation
IN V N E U T R A L IN
(to in v e rte r’s A C n e u tra l in p u t )
IN V H O T 1 IN
( to in v e rte r’s A C H o t 1 in p u t)
IN V H O T 2 IN
(to in v e rte r’s A C H o t 2 in p u t)
IN V N E U T R A L O U T
( fro m in v e rte r’s A C
n e u tra l o u tp u t )
A C - G R O U N D C O N N E C T IO N
(re m o v e g re e n w ire fro m g ro u n d
b u s b a r if n e u tra l is b o n d e d to
g ro u n d fro m p rim a ry s o u rc e )
G R O U N D BU S B A R (in v e rte r’s
in p u t a n d o u tp u t A C g ro u n d)
IN V H O T 1 O U T
( fro m in v e rte r’s
A C H o t 1 o u tp u t)
IN V H O T 2 O U T
( fro m in v e rte r’s
A C H o t 2 o u tp u t)
INVERTER AC TERMINAL
BLOCK (W ires to/from
inverter AC terminals)
EXTERNAL AC TERMINAL
BLOCK (W ires to/from utility/
generator and AC sub-panel
A C H OT 2 OU T
(to m a in b re a k e r o n
L 2 s id e in A C lo a d p a n e l)
A C H OT 1 OU T
( to m a in b re a k e r o n
L1 s id e in A C lo a d p a n e l)
A C N EU TR A L OU TPU T
(to n e u tra l b u s b a r in
A C lo a d p a n e l)
A C H O T 2 IN
( fro m L 2 s id e o f u tility o r g e n e ra to r )
GR OU N D B U SB A R
(fro m u tility /g e n e ra to r g ro u n d
a n d to A C lo a d p a n e l g ro u n d )
A C H O T 1 IN
( fro m L 1 s id e o f u tility o r g e n e ra to r )
A C N E U T R A L IN
(fro m n e u tra l o f u tility o r g e n e ra to r )
Figure 3-12, AC Wiring Connections (MMPxxx-30D Models)
© 2010 Magnum Energy, Inc.
Page 29
3.0 Installation
IN V N E U T R A L IN
(to in v e rte r’s A C n e u tra l in p u t )
IN V H O T IN
(to in v e rte r’s A C H o t in p u t )
IN V N E U T R A L O U T
(fro m in v e rte r’s A C
n e u tra l o u tp u t )
A C - G R O U N D C O N N E C T IO N
(re m o v e g re e n w ire fro m g ro u n d
b u s b a r if n e u tra l is b o n d e d to
g ro u n d fro m p rim a ry s o u rc e )
G R O U N D BU S B A R ( in v e rte r’s
in p u t a n d o u tp u t A C g ro u n d)
IN V H O T 1 O U T
( fro m in v e rte r’s
A C H o t o u tp u t)
INVERTER AC TERMINAL
BLOCK (W ires to/from
inverter AC terminals)
EXTERNAL AC TERMINAL
BLOCK (W ires to/from utility/
generator and AC sub-panel
A C H OT OU T
(to m a in b re a k e r
in A C lo a d p a n e l)
A C N EU TR A L OU TPU T
( to n e u tra l b u s b a r in
A C lo a d p a n e l)
A C H O T IN
(fro m h o t o u t o f u tility o r g e n e ra to r )
GR OU N D B U SB A R
(fro m u tility /g e n e ra to r g ro u n d
a n d to A C lo a d p a n e l g ro u n d)
A C N E U T R A L IN
(fro m n e u tra l o f u tility o r g e n e ra to r )
Figure 3-13, AC Wiring Connections (MMPxxx-60S Models)
Page 30
© 2010 Magnum Energy, Inc.
3.0 Installation
3.9.3
AC Wire Size and Overcurrent Protection
The AC input and output wiring must be sized per the local electrical safety code requirements to
ensure the wires ability to safely handle the inverter’s maximum load current. After determining
the proper AC wire sizes, they are required to be protected from short circuits and overloads by
an overcurrent protection device, and have a means to disconnect the AC circuits.
The MMP enclosure provides AC circuit breakers for the inverter’s AC input. These breakers are
branch circuit rated and can be used as the overcurrent protection and the AC disconnect device
as long as the AC wires used are not smaller than the ‘Minimum Wire Size’ as shown in Table 3-5
for your particular MMP enclosure model and the ‘AC Input/Output Wiring Configuration’ used.
If using a Magnum MS, MS-AE, MS-PAE, or RD Series inverter, the full AC continuous pass-thru
capacity of these inverters is 30 amps for each AC leg1 (AC HOT 1 and AC HOT 2), and requires
a maximum 30 amp breaker on each AC input to protect the inverter’s inputs. This correlates
with the MMPxxx-30D models, which include a dual 30 amp input inverter breaker and requires a
minimum cable size of #10 AWG2 in conduit.
In the MS or RD Series inverters, the AC HOT 1 and AC HOT 2 may be combined to obtain a 60
amps pass-thru capability. When tying the AC HOT 1 and HOT 2 together for a 60 amp continuous
pass-thru capability, the AC input to the inverter requires a 60 amp breaker. This correlates with
the MMPxxx-60S models, which include a single 60 amp breaker and requires a minimum cable size
of #6 AWG2 in conduit. If you are using other circuit breakers/wire sizes, refer to the appropriate
electrical codes for proper sizing requirements.
3.9.4
AC Conductor Wiring
The following steps are basic guidelines for installing and connecting the AC wiring into and out of
the inverter. Refer to Table 3-5 to determine your AC wiring configurations before beginning.
WARNING: To prevent electrical shock, make sure all AC power (inverter, generator,
or utility) is off before making any AC connections inside the MMP enclosure.
Wiring External AC Source and AC Load Panel
1. Route an appropriate cable from a dedicated breaker in the main AC electrical panel through
one of the MMP enclosure’s knockout to the EXTERNAL AC IN/OUT TERMINAL BLOCK (HOT IN/
NEUT IN side).
2. Route an appropriate cable from the EXTERNAL AC IN/OUT TERMINAL BLOCK (HOT OUT/NEUT
OUT Side) through another MMP enclosure knockout to the inverter’s AC electrical sub-panel (or
AC outlets, if using the Magnum inverter models with output breakers).
Wiring Inverter AC Input/Output
1. Route an appropriate cable from the INVERTER AC IN/OUT TERMINAL BLOCK (HOT IN/NEUT
IN side) to the inverter’s AC input terminals.
2. Route an appropriate cable from the INVERTER AC IN/OUT TERMINAL BLOCK (HOT OUT/NEUT
OUT side) to the inverter’s AC output terminals.
Wiring the AC Ground
Route the following AC ground wires; 1) the main AC panel’s ground busbar, 2) the ground wire
from the inverter’s AC sub panel’s ground busbar (or the ground connection on the outlets, if using
the Magnum inverter with output breakers), and 3) the AC ground wire from the inverter; and
connect to the “AC GROUND” busbar in the MMP enclosure (Item 8 in Figures 2-2 and 2-4).
AC Wiring Inspection
After verifying all AC connections are correct, and all AC terminal screws are torqued correctly
(refer to Tables 3-1 to 3-3), replace the inverter’s AC wiring access cover and the covers on the
main electrical panel/sub-panel.
Note 1 - On Magnum MS2012/MS2000 (-15B and -20B) breaker models, the pass-thru current is limited by
the output breaker size.
Note 2 - This wire must be copper with a minimum rating of 300V, 75°C.
© 2010 Magnum Energy, Inc.
Page 31
3.0 Installation
3.9.5
AC Wiring Configurations
The following table provides the different wiring configurations for installing and connecting the
AC conductors into and out of the inverter (refer to Figures 3-14 to 3-17 for installation drawings
showing these configurations).
Table 3-5, AC Input/Output Wiring Configurations
SI/SO (30A)
[Single In/
Single Out
(30A)]
SI/SO (60A)
[Single In/
Single Out
(60A)]
DI/SO
[Dual In/
Single Out]
DI/DO
[Dual In/
Dual Out]
AC Source1
Required
120 VAC @ < 30
amps
120 VAC @
> 30 amps
(60 amps maximum).
120/240 VAC
(or 2 separate legs of
120 VAC)
@ < 30 amps per leg
120/240 VAC
(or 2 separate legs of
120 VAC)
@ < 30 amps per leg
Reason to
Use
Have a 120 VAC
source that is
< 30 amps.
Requires a
separate inverter
sub-panel4.
Have a 120 VAC
source that is > 30
amps.
Requires a
separate inverter
sub-panel.
Want dedicated
charging and
dedicated pass-thru
while the AC source
is on.
Requires a
separate inverter
sub-panel.
May need to power
240 VAC loads
when AC source
is on (requires
120/240 VAC source).
Requires a separate
inverter sub-panel.
Appropriate
MMP Models
MMP175-30D,
MMP250-30D
MMP175-60S,
MMP250-60S
MMP175-30D,
MMP250-30D
MMP175-30D,
MMP250-30D
Appropriate
Magnum
Inverter
Models
MS Series,
MS-AE Series,
MS-PAE Series,
RD Series
MSxx12, MS4024,
MS-AE Series,
MS-PAE Series,
RD Series
MSxx12,
MS4024,
RD Series
MSxx12, MS4024,
MS-AE Series,
MS-PAE Series,
RD Series
AC Input
Breaker
Provided
30A
(one pole of dual
pole breaker)
60A
(single pole)
30A
(dual pole)
30A
(dual pole)
#10 AWG
(In & Out)
#6 AWG
(In & Out);
Can be split to two
#10 AWG
(for HOT 1
& HOT 2)
#10 AWG
(In & Out)
#10 AWG
(In & Out)
Minimum AC
Wire Size5
Maximum
Inverter
Pass-thru
capacity
3600W
(30A @ 120 VAC)
5000W2
(60A @ 120 VAC)
3600W
(30A @ 120 VAC)
5000W2
(2 legs of 30A @
120/240 VAC or
2 legs of 30A @
120 VAC)3
Wiring
Diagram
Figure 3-14
Figure 3-15
Figure 3-16
Figure 3-17
Note
Note
Note
Note
1:
2:
3:
4:
AC Source is from either the utility/grid power or an AC generator.
Enclosure capacity rated for 5000 Watts maximum.
If 2 legs of 30A @ 120 VAC are used, they must be from the same source
The MS2012 and MS2000 models with integral branch circuit rated output breakers (i.e. MS201220B) allows direct wiring from the unit to the load and do not require an inverter sub-panel.
Note 5: Based on AC input breaker provided
Page 32
© 2010 Magnum Energy, Inc.
3.0 Installation
M M P x x x-3 0D E n c lo s u re
(w ith M a g n u m In v e rte r)
S IN G L E IN / S IN G L E O U T (3 0A )
A C W irin g
N EU T IN
GR OU N D
H OT 1 IN
If the m ain panel
has a neutral to
ground
connection ,
unscrew this
‘Ground to
N eutral’ w ire
connection from
the GR OU N D
busbar. T his w ill
isolate the neutral
from ground to
prevent m ultiple
‘N eutral to
Ground’ bonds.
N EU T IN
HO T 1 IN
N EU T O UT
A C IN
(to in verter
A C In p u t)
NE UT OU T
H OT 1 O UT
HO T 1 OU T
A C OU T
(fro m in verter
A C Ou tp u t)
A C OU T
(to A C L o ad s)
A C IN
(fro m Grid /Gen)
ON
ON
ON
OF F
ON
ON
O FF
O FF
O FF
ON
ON
ON
OF
FFF
ON
OO N
ON
OF F
ON
OF F
ON
ON
O FF
120
VA C
OF F
S u b -P a n e l a n d O u tle ts
(In v e rte r A C L o a d s )
O FF
ON
O FF
120
VA C
OF F
OFF
O FF
ON
OO FF
OFF
M a in P a n e l
( U tility /G e n e ra to r ≤3 0 A )
Figure 3-14, AC Wiring for Single In - Single Out (30 A) Configurations
© 2010 Magnum Energy, Inc.
Page 33
3.0 Installation
M M P x x x-6 0S E n c lo s u re
(w ith M a g n u m In v e rte r)
S IN G L E IN / S IN G L E O U T (6 0 A )
A C W irin g
N EU T IN
A C GR OU N D
(to
in verter
A C In p u t)
If the m ain panel
has a neutral to
ground
connection ,
unscrew this
‘Ground to
N eutral’ w ire
connection from
the GR OU N D
busbar. T his w ill
isolate the neutral
from ground to
prevent m ultiple
‘N eutral to
Ground’ bonds.
`
`
GR OU ND
N EU T IN
NE UT OU T
H OT 1 IN
H OT 1 IN
N EU T O UT
HO T 1 OU T
H OT 1 OU T
A C OU T
A C IN
(fro m
(to
in verter
in verter
A C Ou tp u t) A C In p u t)
A C OU T
(to A C L o ad s)
A C IN
(fro m Grid /Gen)
ON
OF F
ON
O FF
O FF
O FF
ON
N
O
ON
ON
OF
FFF
O
ON
ON
OO N
N
ON
OF F
ON
O FF
ON
ON
ON
ON
ON
OF F
120
VA C
O FF
120
VA C
OF F
ON
S u b- P a n e l a n d O u tle ts
(In v e rte r A C L o a d s )
O FF
ON
OF F
120
VA C
O FF
120
VA C
OF F
OFF
O FF
ON
OO FF
FF
OFF
M a in P a n e l
(U tility /G e n e ra to r ≤6 0A )
Figure 3-15, AC Wiring for Single In - Single Out (60 A) Configurations
Page 34
© 2010 Magnum Energy, Inc.
3.0 Installation
M M P x x x-3 0D E n c lo s u re
(w ith M a g n u m In v e rte r)
D U A L IN / S IN G L E O U T
A C W irin g
N EU T IN
If the m ain panel
has a neutral to
ground
connection ,
unscrew this
‘Ground to
N eutral’ w ire
connection from
the GR OU N D
busbar. T his w ill
isolate the neutral
from ground to
prevent m ultiple
‘N eutral to
Ground’ bonds.
GR OU N D
N EU T IN
H OT 1 IN
H OT 2 IN
NE UT OU T
HO T 2 IN
HO T 2 OU T
H OT 2 O UT
HO T 1 IN
A C IN
(to in verter
A C In p u t)
N EU T O UT
A C OU T
(fro m in verter
A C Ou tp u t)
A C OU T
(to A C L o ad s)
A C IN
(fro m Grid /Gen)
ON
ON
ON
ON
OF F
OF F
ON
ON
O FF
O FF
O FF
ON
ON
OF F
ON
OF
FFF
ON
O FF
OO N
ON
OF F
ON
ON
O FF
ON
O FF
120
VA C
OF F
OFF
O FF
ON
OO FF
OFF
S u b -P a n e l a n d O u tle ts
(In v e rte r A C L o a d s )
120
VA C
M a in P a n e l
(U tility /G e n e ra to r ≤3 0 A p e r le g )
Figure 3-16, AC Wiring for Dual In - Single Out Configurations
© 2010 Magnum Energy, Inc.
Page 35
3.0 Installation
M M P x x x-3 0D E n c lo s u re
(w ith M a g n u m In v e rte r)
D U A L IN / D U A L O U T
A C W irin g
HO T 1 IN
N EU T IN
If the m ain panel
has a neutral to
ground
connection ,
unscrew this
‘Ground to
N eutral’ w ire
connection from
the GR OU N D
busbar. T his w ill
isolate the neutral
from ground to
prevent m ultiple
‘N eutral to
Ground’ bonds.
GR OU N D
N EU T IN
H OT 2 IN
H OT 1 IN
HO T 2 IN
N EU T O UT
A C IN
(to in verter
A C In p u t)
NE UT OU T
HO T 1 OU T
H OT 1 O UT
H OT 2 O UT
HO T 2 OU T
A C OU T
(fro m in verter
A C Ou tp u t)
A C OU T
(to A C L o ad s)
A C IN
(fro m Grid /Gen)
ON
OF F
ON
O FF
O FF
O FF
ON
ON
ON
OF
FFF
ON
ON
OO N
ON
O FF
ON
OF F
ON
ON
ON
ON
ON
OF F
120
VA C
O FF
ON
120
VA C
OF F
ON
OF
FF
F
O
S u b- P a n e l a n d O u tle ts
(In v e rte r A C L o a d s )
O FF
O FF
240
VA C
OF F
OFF
O FF
ON
OO FF
OFF
M a in P a n e l
(U tility /G e n e ra to r ≤3 0 A p e r le g )
Figure 3-17, AC Wiring for Dual In - Dual Out Configurations
Page 36
© 2010 Magnum Energy, Inc.
3.0 Installation
3.10 MMP/Inverter System Grounding
The MMP/inverter system uses both AC and DC electrical systems, therefore each electrical system
is required to be properly connected to a permanent, common “ground” or “earth” reference. A
MMP/inverter system that is properly grounded limits the risk of electrical shock, reduces radio
frequency noise, and minimizes excessive surge voltages induced by lightning. To understand how
the conductors in the electrical circuit will be connected to the system ground, the following terms
should be understood (also refer to Figure 3-18):
• Grounded Conductor (GC): The wire/cable in the electrical system that normally carries current
(usually the AC neutral and/or the DC negative); and, is intentionally connected or “bonded” to
the ground system. This wire or the ends of this wire must be colored white or gray.
• Equipment Grounding Conductor (EGC): A wire/cable that does not normally carry current and
is used to connect the exposed metal parts of equipment — that might be accidentally energized
— to the grounding electrode system or the grounded conductor. This wire or the ends of this
wire must be green, or green with a yellow stripe; or, this wire can be bare copper.
• Grounding Electrode Conductor (GEC): The wire/cable that does not normally carry current,
and connects the grounded conductor and/or the equipment grounding conductor to the
grounding electrode at the service equipment.
• Grounding Electrode (GE): A ground rod or conducting element that establishes an electrical
connection to the earth or common ground reference.
• System bonding jumper (SBJ): The connection between the grounded circuit conductor in the
electrical system and the equipment grounding conductor at a separately derived system.
There are two types of grounding - equipment grounding and system grounding.
The exposed metal parts of the equipment in the system usually don’t carry electricity. However, if
the exposed metal becomes electrified by a live wire, a person touching this live part could complete
the electrical circuit and receive a shock. Equipment grounding prevents shock by connecting all
the exposed metal parts of equipment (via Equipment Grounding Conductors - EGC) together at
a common ground point (Ground BusBar - GBB). This common ground point - installed in the
service disconnect panel for each electrical system (AC and DC) - is then connected (via Grounding
Electrode Conductor - GEC) to the common ground reference, such as a ground rod (Grounding
Electrode - GE). This connection to earth is made at only one point in each electrical system;
otherwise, parallel paths will exist for the currents to flow. These parallel current paths would
represent a safety hazard and are not allowed in installations wired per the NEC/CEC.
System grounding takes one of the current-carrying conductors (Grounded Conductor - GC) and
attaches it to the common ground point (Ground BusBar - GBB), usually by a System Bonding
Jumper (SBJ) in each electrical service disconnect panel. On the AC side, that is the neutral
conductor (GC-AC); on the DC side, it’s the negative conductor (GC-DC). The closer the grounding
connection is to the source, the better the protection from high voltage surges due to lightning.
PO S
N EG
GN D
GN D
N E UT
HOT 1
D C E le c tric a l
S y s te m
DC
S OU R C E
H OT 1
G C -A C
H OT 2
SB J
N EU T
D C S ID E
M AIN A C P AN EL
A C S IDE
AC
S OU R C E
HOT 2
M AG NUM
I NV E RTE R
A C E le c tric a l
S y s te m
GB B
GB B
or
G E C -A C
or
A C s ide dedic ated
BAT
SB J
or
GE
BAT
G C -D C
M M P E NCLO S URE
G E C -D C
G ro u n d in g S y s te m
or
GE
A C and D C s ides s hared
GE
D C s ide dedic ated
Figure 3-18, Grounding System for Inverter with MMP Enclosure
© 2010 Magnum Energy, Inc.
Page 37
3.0 Installation
3.10.1
Sizing the Grounding Electrode Conductors
AC Side - The size of the AC Grounding Electrode Conductor (GEC –AC) depends on the size of
the largest ungrounded conductor feeding the AC load center. One #8 AWG (8.4 mm2) copper
conductor will serve as an AC Grounding Electrode Conductor (GEC –AC) for AC power conductors
smaller than and including #2 AWG (33.6 mm2) copper. See Table 3-6 for additional values.
Table 3-6, AC Grounding Electrode Conductor Sizing
Size of Largest Ungrounded
Conductor
Minimum Size of Grounding
Electrode Conductor
#2 AWG or smaller
#8 AWG (8.4 mm2)
#1 to #1/0 AWG
#6 AWG (13.3 mm2)
#2/0 or #3/0 AWG
#4 AWG (21.1 mm2)
Over #3/0 AWG
through 350 kcmil
#2 AWG (33.6 mm2)
DC Side - To size the DC grounding electrode conductor, you must first determine which one of the
following three methods will be used to connect the DC and AC grounding points in the inverter’s
two electrical systems to the common “earth” ground.
Info: There are many variables to consider when choosing the size of the DC grounding
electrode conductor. The MMP enclosure provides the means to ground both the AC and
DC to a single ground, and when feasible, the Single Connection to Ground (Method
1) is recommended. In this method, the NEC allows a #6 AWG wire which makes the
overall installation simpler and less costly.
1.
Single Connection to Ground (Method 1): The AC Grounding Electrode Conductor (GEC
– AC) is bonded to the DC ground point and the DC Grounding Electrode Conductor (GEC – DC)
is the only connection to the grounding electrode, which must be a rod, pipe, or plate electrode
(see Figure 3-19).
Normally the size of the DC Grounding Electrode Conductor (GEC – DC) must be no less than the
size of the Battery Bank Negative Cable. However, in this method, since there is only one connection
to the ground rod, the NEC allows an exception that the DC grounding electrode conductor is
not required to be larger than #6 AWG (13 mm2) copper. The reasoning for allowing this smaller
grounding electrode conductor is that it is only required to stabilize the system voltage with respect
to earth, and the other properly-sized conductors in each electrical system will safely carry any
fault currents if they occur.
PO S
N EG
GN D
GN D
N E UT
HOT 1
D C E le c tric a l
S y s te m
DC
S OU R C E
H OT 1
G C -A C
H OT 2
N EU T
GB B
G E C -A C
D C S ID E
M AIN A C P AN EL
A C S IDE
AC
S OU R C E
HOT 2
M AG NUM
I NV E RTE R
A C E le c tric a l
S y s te m
BAT
G C -D C
BAT
SB J
SB J
GB B
M M P E NCLO S URE
G E C -D C
G ro u n d in g S y s te m
GE
D C s ide dedic ated
Figure 3-19, Single Connection to DC Ground Rod (Method 1)
Page 38
© 2010 Magnum Energy, Inc.
3.0 Installation
2.
Multiple Connections to Ground - Single Electrode (Method 2): When the AC and DC
service panels are near each other, then the AC Grounding Electrode Conductor (GEC – AC) and
DC Grounding Electrode Conductor (GEC – DC) can be connected to a single Grounding Electrode
(see Figure 3-20). In this method - since there are multiple connections to the DC Grounding
Electrode (GEC – DC) - the size of the DC grounding electrode conductor cannot be smaller than
the largest conductor in the DC system (usually the battery-to-inverter cable).
PO S
N EG
GN D
GN D
N E UT
HOT 1
D C E le c tric a l
S y s te m
DC
S OU R C E
H OT 1
G C -A C
H OT 2
N EU T
D C S ID E
M AIN A C P AN EL
A C S IDE
AC
S OU R C E
HOT 2
M AG NUM
I NV E RTE R
A C E le c tric a l
S y s te m
BAT
SB J
SB J
GB B
BAT
G C -D C
GB B
M M P E NCLO S URE
G ro u n d in g S y s te m
G E C -A C
G E C -D C
GE
A C and D C s ides s hared
Figure 3-20, Multiple Connections to DC Ground Rod (Method 2)
3.
Multiple Connections to Ground - Multiple Electrodes (Method 3): This method uses
a separate Grounding Electrode for the DC system and the AC system (see Figure 3-21). In this
method — since there are multiple connections to the DC Grounding Electrode (GEC – DC) — the
size of the DC grounding electrode conductor cannot be smaller than the largest conductor in the
DC system (usually the battery-to-inverter cable).
The DC Grounding Electrode (GE – DC) must be bonded to the AC Grounding Electrode (GE – AC)
to make a grounding electrode system; this Bonding Conductor (BC) cannot be smaller than the
largest grounding electrode conductor, either AC or DC.
PO S
N EG
GN D
GN D
N E UT
HOT 1
D C E le c tric a l
S y s te m
DC
S OU R C E
H OT 1
G C -A C
H OT 2
N EU T
GB B
D C S ID E
M AIN A C P AN EL
A C S IDE
AC
S OU R C E
HOT 2
M AG NUM
I NV E RTE R
A C E le c tric a l
S y s te m
BAT
G C -D C
BAT
SB J
SB J
GB B
M M P E NCLO S URE
G E C -A C
GE
A C s ide dedic ated
G ro u n d in g S y s te m
BC
G E C -D C
GE
D C s ide dedic ated
Figure 3-21, Multiple Connections to DC Ground Rod (Method 3)
© 2010 Magnum Energy, Inc.
Page 39
3.0 Installation
3.10.2
Equipment Grounding Conductor
The MMP enclosure and all other non-current-carrying exposed metal surfaces in the entire electrical
system that may be accidentally energized must be grounded. The equipment-grounding conductor
must be sized to safely carry the maximum ground-fault current likely to be imposed on it from
where a ground-fault may occur.
AC Side - When the AC circuit breaker provided in the MMP enclosure is being used as the inverter’s
AC overcurrent protection device, the AC Equipment Grounding Conductor (EGC – AC) for the
inverter is based on the AC breaker size provided (#10 AWG for all MMP models). Connect the
AC equipment-grounding conductor from the inverter’s AC ground connection to the AC Ground
Busbar (GBB) in the MMP enclosure (Item 8 in Figure 2-2 or 2-4).
DC Side - When the DC circuit breaker provided in the MMP enclosure is being used as the inverter’s
DC overcurrent protection device, the DC Equipment Grounding Conductor (EGC – DC) for the
inverter is based on the DC breaker size provided (#6 AWG for MMP175 models, #4 AWG for
MMP250 models). Connect the DC equipment-grounding conductor from the inverter’s DC ground
connection to the DC Ground Busbar (GBB) in the MMP enclosure (Item 20 in Figure 2-2 or 2-4).
If you are using AC or DC overcurrent protection that is different than that provided in the MMP
enclosure, or installing optional DC breakers inside the MMP enclosure, in accordance with the
NEC/CEC, you must determine your equipment-grounding conductors based on the ampere rating
of the overcurrent device protecting the circuit conductors. Use Table 3-7 to help determine the
equipment-grounding conductor. If the circuit conductors are oversized to compensate for voltage
drop, the equipment-grounding conductor must also be oversized proportionally.
Table 3-7, Equipment Grounding Conductor Sizing
3.10.3
Rating of Overcurrent
Device
Minimum Size of Copper
Ground Wire
15 amp
#14 AWG
20 amp
#12 AWG
30 - 60 amp
#10 AWG
100 amp
#8 AWG
200 amp
#6 AWG
300 amp
#4 AWG
400 amp
#3 AWG
System Bonding Jumper
The MMP enclosure provides the single point of ground [System Bonding Jumper (SBJ)] for the
AC and DC system. If the MMP enclosure is the central connection point for all ground wiring
(usually in an off-grid system) and there is no other connection from AC neutral or DC negative
to ground in the AC or DC system, then leave the ground bond connections in place. Remove any
other neutral-ground connection in the AC system, such as in other electrical sub-panels; or, any
negative-ground connection in the DC system.
For utility connected systems where the neutral and ground are already bonded in the main utility
circuit breaker box (AC distribution panel), the GREEN GROUND/NEUTRAL bonding wire MUST BE
REMOVED from the MMP enclosure. See Section 3-11 to remove this Neutral-Ground connection.
Info: Inverters and portable generators that have electrical outlets usually have the
neutral and ground bonded internally. These types of devices are not recommended to
be connected to the MMP/inverter system as they would first need to be modified to
separate the neutral and ground bonding internally.
For systems or devices that connect the DC negative to ground independently (i.e., separate
DC main electrical distribution panel or PV-GFP device), the Negative to Ground busbar (Item 1,
Figure 2-2 or 2-4) MUST BE REMOVED inside the MMP enclosure. See Section 3-12 to remove this
Negative-Ground connection.
Page 40
© 2010 Magnum Energy, Inc.
3.0 Installation
3.11 Removing the AC Neutral to Ground Connection
In installations where the MMP enclosure is powered from utility power or large permanently installed
generator systems, the AC neutral to ground connection is normally provided inside the main AC
electrical distribution panel. In these systems, the factory-installed neutral to ground connection
in the MMP enclosure must be removed to prevent multiple neutral-to-ground bonds. See Figure
3-22 to help remove the neutral to ground connection from the AC Ground Busbar.
Steps to remove the neutral to ground
connection:
1. Inside the MMP enclosure, locate the green
wire with the NEUTRAL - GROUND CONNECTION label (Item 7, in Figure 2-2 or 2-4). This
green wire connects the neutral and ground
inside the MMP enclosure.
Neutral to
Ground
Connection
(Green Wire)
2. Loosen the screw and remove this green
wire from the AC Ground Busbar (Item 8,
in Figure 2-2 or 2-4). Note: After this wire
is removed, remember to tighten the loose
screw back into the busbar to prevent it from
being lost.
3. With this green wire removed, wrap electrical tape around the bare end to insulate the
wire and prevent it from making contact
with any metal. Secure the green wire out
of the way.
AC Ground
Busbar
Figure 3-22, Removing the AC Neutral
to Ground Connection
3.12 Removing the DC Negative to Ground Connection
The MMP enclosure provides the single point of ground for the DC system by connecting the DC
Shunt (battery negative connection point) to the DC Ground Stud using the DC Negative to Ground
Busbar (Item 1, in Figure 2-2 and 2-4). If the single negative-ground connection is made elsewhere
in the DC system — either at the battery terminal, inside a charge controller, or if you are installing
a PV-Ground Fault Protection (PV-GFP) device — this busbar must be removed to prevent multiple
negative-ground bonds. See Figure 3-23 to help remove the Negative to Ground Busbar.
Steps to remove the DC negative to ground
connection:
1. Inside the MMP enclosure, locate the Negative to Ground Busbar (Item 1, in Figure 2-2
and 2-4). This busbar connects negative and
ground inside the MMP enclosure.
2. Remove the 5/16” flange nut (1/2” wrench)
holding the busbar to the DC Ground Stud
(Item 13, in Figure 2-2 or 2-4), and then remove the 3/8” brass bolt and washer (9/16”
wrench) from the bottom terminal of the DC
Shunt (Item 12, in Figure 2-2 or 2-4).
3. After the Negative to Ground Busbar is removed; reattach the flange nut on the DC
Ground Stud and the brass bolt/washer back
onto the DC Shunt. Ensure the hardware
on the bottom terminal of the DC Shunt is
stacked correctly. Note: Refer to Figure 310 or 3-11 to correctly stack the DC Shunt
hardware.
© 2010 Magnum Energy, Inc.
DC Ground
Stud
Bottom terminal
(DC Shunt)
Negative to Ground
Busbar
Figure 3-23, Removing the DC
Negative to Ground Busbar
Page 41
3.0 Installation
3.13 Wiring Accessories
The NEC/CEC requires the insulation of all conductors inside the MMP enclosure to be rated for
the highest voltage present. The MMP enclosure is designed to work with 120/240VAC inverters,
therefore, the voltage rating of the communications cables inside the MMP enclosure must be rated
for 300 volts or higher to be code compliant.
With the purchase of the MMP enclosure, Magnum has included three six-foot, yellow communication
cables with 300-volt rated insulation. These cables — shown below — are provided to make
connections between Magnum inverters and accessories easier and code compliant:
Info: These cables carry less than 30 volts and are thus considered a “limited energy
circuit”, which is normally not required to be installed in conduit.
Figure 3-24 shows the ‘REMOTE’ cable. It
allows a remote control — such as the MERC (Remote Control) or ME-ARC (Advance
Remote Control) — to be connected to the
MMP enclosure. This cable is a 6’ (1.83 m),
4-conductor, telephone-type cable with a RJ14
(m) connector and a blue REMOTE label on
each end. One end of this cable is connected
to the remote and the other end is routed
inside the MMP enclosure, and connected
to the inverter’s REMOTE port as shown in
Figure 3-27.
Figure 3-24, REMOTE Communication Cable (300V)
Figure 3-25 shows the ‘NETWORK’ cable.
It allows Magnum accessories — like the
ME-AGS (Auto Generator Start) or ME-BMK
(Battery Monitor) — to be connected to the
MMP enclosure. This cable is a 6’ (1.83 m),
2-conductor, telephone-type with a RJ14 (m)
connector and a green NETWORK label on
each end. One end of this cable is connected
to the accessory and the other end is routed
inside the MMP enclosure, and connected to
the inverter’s NETWORK port as shown in
Figure 3-27.
Figure 3-25, NETWORK Communication Cable (300V)
Figure 3-26 shows the ‘EXTENSION’ cable.
It allows the Magnum ME-BTS (Battery
Temperature Sensor) to be connected to
the MMP enclosure. This is a 6’ (1.83 m), 4conductor, telephone-type cable with a RJ14
(m) connector on one end and a RJ14 (f) plug
on the opposite end. The female plug end
connects to the ME-BTS (Battery Temperature
Sensor). After connecting to the ME-BTS,
this extension cable is routed inside the MMP
enclosure and connects to the inverter’s BTS
port as shown in Figure 3-27.
Figure 3-26, Extension Cable (300V)
Page 42
© 2010 Magnum Energy, Inc.
3.0 Installation
M E -A G S -N
N E TW O R K
N E TW O R K C om m unic a tion C a ble
(3 0 0 v olt ra te d)
R E M O TE C om m unic a tion C a ble
(3 0 0 v olt ra te d)
F ro n t c o v e r o f M M P e n c lo s u re
( b a c k s id e )
N E TW O RK
R E MO T E
R E MO TE
M E -B T S
B TS
M E -R C o r
M E -A R C
E x te ns ion C a ble (3 0 0 v olt ra te d)
Figure 3-27, Accessory Wiring using 300 Volt Communications Cables
© 2010 Magnum Energy, Inc.
Page 43
3.0 Installation
3.14 Installation Checklist
Use this checklist as a final review to ensure all essential steps to install the MMP enclosure have
been made before proceeding with the functional test.
Mounting
The MMP enclosure/inverter system is securely mounted in a clean, dry, and ventilated area.
The MMP enclosure/inverter system is not mounted in the same enclosure as maintenance-free
or vented type vented batteries.
The MMP enclosure is mounted in a vertical only position.
There is adequate clearance to access the front and to view/adjust the remote (if installed).
DC Wiring (use Table 3-4 to determine the DC wire size).
Inverter Side with Magnum Inverter:
The inverter is correctly placed on the MMP enclosure with the inverter’s DC terminals attached
onto the inverter DC Negative and Positive Busbars inside the MMP enclosure.
Inverter Side without Magnum Inverter:
An appropriately sized DC cable is routed from the inverter’s DC positive (+) terminal and
attached to the top terminal of the Inverter DC disconnect inside the MMP enclosure.
An appropriately sized DC cable is routed from the inverter’s DC negative (-) terminal and
attached to the top terminal of the DC Shunt inside the MMP enclosure.
Battery Bank Side:
An appropriately sized DC cable is routed from the positive (+) battery terminal and attached
to the bottom terminal of the Inverter DC disconnect inside the MMP enclosure.
An appropriately sized DC cable is routed from the negative (-) battery terminal and attached
to the bottom terminal of the DC Shunt inside the MMP enclosure.
The DC cable connections and DC hardware is stacked (Figure 3-10 or 3-11) and torqued (Tables
3-1 to 3-3) correctly.
AC Wiring (use Table 3-5 to determine the AC wiring configuration and to find the AC wire size).
In and Out of Inverter: The AC wires are appropriately sized and routed from the INVERTER AC
IN/OUT TERMINAL BLOCK (inside MMP enclosure) to the inverter’s AC input/output terminals.
To Main AC Electrical Panel: The AC wires are appropriately sized and are routed from the Grid/
Gen side of the EXTERNAL AC IN/OUT TERMINAL BLOCK (inside MMP enclosure) to the circuit
breaker in the Main AC electrical panel powered by the utility or generator (i.e., main panel).
To Inverter AC Load Panel: The AC wires are appropriately sized and routed from the AC Load
side of the EXTERNAL AC IN/OUT TERMINAL BLOCK (inside MMP enclosure) to the main circuit
breaker in the electrical panel powered by the inverter (i.e., sub-panel).
The AC wires connected to the terminal blocks are torqued correctly (see Tables 3-1 to 3-3).
Grounding
There is only one bonding connection to ground for the DC electrical system (negative to ground)
and one bonding connection to ground for the AC electrical system (neutral to ground). These
bonding connections may be connected to the same grounding electrode system (ground rod). If
separate electrodes are used, they must be bonded together.
The exposed metal parts of equipment are properly grounded.
Equipment grounding conductors are properly sized.
Electrical Connections
Connectors are listed for the intended use and environment (inside, outside, wet, etc.).
Pressure/screw terminals tightened to the recommended torque specification.
Terminals containing more than one conductor are listed for multiple conductors.
Connectors using flexible, fine-stranded conductors are listed for use with such conductors.
Re-torque all electrical terminal connections in the inverter to tighten any connections that
may have loosened since the initial installation.
Page 44
© 2010 Magnum Energy, Inc.
3.0 Installation
Conductors and General Wiring Methods
Conductors are rated for the application and the environment.
Standard building-wire conductors and appropriate wiring methods are used.
Note: Welding cables, marine, locomotive (DLO), and auto battery cables don’t meet NEC /CEC
requirements. Flexible RHW or THW cables are available, but these cables require very limited,
specially listed terminals. When the battery conductors leave the battery enclosure, the conductors
must be of a type listed for use in conduit (RHW or THW).
The DC and AC color codes for the ground conductors are the same - grounded conductors are
white and equipment-grounding conductors are green, green/yellow, or bare (no insulation).
All wiring insulation must have a minimum rating of 150V, 75°C when using only 120 VAC power/
inverter; or with a minimum rating of 300V, 75°C when using 120/240VAC power/inverter.
Strain reliefs/cable clamps or conduit are used on all cables and cords.
Conductors between the inverter and battery bank are required to be installed in conduit.
No multi-wire branch circuits when single, 120 VAC inverters are connected to 120/240 VAC
load centers.
Note: A multi-wire branch circuit is a three-wire circuit with a shared neutral for two, 120 VAC
branch circuits.
Overcurrent Protection
Properly sized and rated disconnects and overcurrent devices are used in the ungrounded
conductors in each circuit (AC and DC).
Overcurrent devices in the DC circuits are listed for DC operation.
DC overcurrent protection is provided at the batteries when they are located in a separate room,
or more than 5 feet away from the MMP enclosure.
The DC overcurrent protection device and battery cables to the inverter are sized for the
inverter’s DC input current.
Note: Inverter’s DC input current is calculated using rated AC output in watts, divided by lowest
battery voltage, divided by inverter efficiency at that power level.
When the DC Disconnect inside the MMP enclosure is not used as the DC overcurrent device, high
interrupt, listed, DC-rated fuses or circuit breakers must be used in the battery cable circuits.
Batteries
Battery terminals and other live parts are guarded, and adequate working space around the
battery bank is provided.
Batteries are installed in well-vented areas (garages, outbuildings) and not in living areas.
Adhere to the “IMPORTANT BATTERY SAFETY INSTRUCTIONS” at the beginning of this
manual.
Marking
Battery bank is labeled with maximum operating voltage, equalization voltage, and polarity.
Utility Back-up Systems: Exterior visible sign indicating the building contains an inverter backup system and identifies the locations of the disconnects.
An electrical system supplied by a 120 VAC only inverter must include a label warning against
connecting multi-wire branch circuits.
All required “warning” and “caution” signs are installed in the proper locations, as required in
the NEC/CEC.
Inspection
Electrical inspection complete and Certificate of Electrical Inspection issued by the local Authority
Having Jurisdiction (AHJ). The local AHJ or inspector has the final say on what is or is not acceptable.
Local codes may modify the requirements of the NEC/CEC.
Part of this checklist is obtained from the Photovoltaic Electrical Power Systems Inspector/Installer Checklist
created by John Wiles, Southwest Technology Development Institute, New Mexico State University, June 2006
© 2010 Magnum Energy, Inc.
Page 45
3.0 Installation
3.15 Functional Test
After all electrical connections from the MMP enclosure to the inverter, batteries, AC source, and
sub-panel have been completed; follow these steps and refer to Figure 3-28 to test the installation
of the MMP enclosure and verify proper operation of the BYPASS switch breakers.
WARNING: During this Functional Test, the front cover is removed and exposes
personnel to potential dangerous voltages and shock hazards inside the MMP enclosure
that may cause damage, injury, or death. If you do not have experience working with
AC and DC voltage circuits, do not attempt this test - use an experienced electrical
installer.
CAUTION: During this Functional Test, if any step cannot be verified or is incorrect,
stop and recheck/correct the connections before proceeding to the next step.
1. Turn OFF all AC breakers (i.e., INV BYP, INV IN and INV OUT) in the MMP enclosure.
CAUTION: Use a multimeter to verify the correct DC voltage for your particular inverter
model (i.e., 24-volt battery bank for a 24-volt inverter) and ensure the polarity of the
battery voltage is correct [battery positive (+) connected to the inverter positive terminal
thru the DC circuit breaker and battery negative (-) connected to inverter negative
terminal thru the DC shunt].
CAUTION: Prior to turning on the inverter, turn OFF all inverter loads in the Inverter
Load panel (i.e., sub-panel).
2. After verifying the proper battery bank voltage for your inverter and the battery cable
connections are the correct polarity, apply battery power to the inverter by turning the Inverter
DC disconnect breaker to the ON (up) position.
3. Turn the inverter ON.
a. Connect an AC voltmeter to the Inverter Output Terminals and verify the correct AC
output voltage of the inverter (depends on your inverter AC output voltage).
Info: If the inverter does not turn on - verify the DC connections to/from the inverter to
the battery, and/or refer to the Troubleshooting section for your particular inverter.
Info: If the inverter has a Search mode feature, the inverter’s AC full output voltage
will not be present/correct until Search is turned OFF, or by connecting a large enough
light bulb to bring the inverter out of Search. DO NOT connect anything but a light bulb
until all wiring and voltages are confirmed to be correct.
If using a Magnum inverter, use a light bulb greater than 5 watts (5 watts is the default
setting) to bring the inverter out of Search mode; or, the Search mode can be turned
OFF with a remote control (ME-RC or ME-ARC).
4. Turn ON the INV OUT1 breaker(s) in the MMP enclosure.
a. Ensure the inverter AC output voltage is passing thru the INV OUT (Inverter Output) breaker
by verifying the correct output voltage is present on the AC Output Terminals.
5. Turn ON the INV BYP2 breaker(s) in the MMP enclosure.
a. Ensure the inverter AC output voltage is no longer present on the AC Output Terminals.
6. Apply power from an external AC source (utility or AC generator) to the AC Input Terminals.
a. Connect an AC voltmeter to the Inverter Output Terminals and verify the AC voltage from
the external AC source is present. Move the AC voltmeter to the AC Output Terminals and check
that the AC source power is passing thru the INV BYP (Inverter Bypass) breaker by verifying
the AC source voltage present earlier is also present on the AC Output Terminals.
Page 46
© 2010 Magnum Energy, Inc.
3.0 Installation
7.
Turn ON the INV OUT2 and INV IN breaker(s) in the MMP enclosure.
a. Ensure the AC source power is passing thru the INV IN (Inverter Input) breaker by
verifying the AC source voltage present earlier (in step 6) is also present on the AC Output
Terminals.
8. After all the AC voltage checks pass, install the front cover and manually open and close all
circuit breakers, checking for correct alignment and free operation.
If all the steps pass, the MMP enclosure is ready for use. If the any of the steps fails, refer to
Installation section and recheck your wiring connections and/or refer to the Troubleshooting section
for your inverter.
Note 1 - On MMPxxx-60S models, the INV OUT and INV IN breakers are physically ganged together and
turn ON and OFF as a single breaker.
Note 2 - The INV BYP and INV OUT breakers are interlocked together. Physically turning ON one will turn
OFF the other and vice versa.
MMP ENCLOSURE (AC SIDE)
120 V
INVERTER INPUT TERMINALS
120 V
240 V
120 V
120 V
INVERTER OUTPUT TERMINALS
120 V
240 V
120 V
(TO INVERTER’S AC INPUT)
(FROM INVERTER’S AC OUTPUT)
USE AN AC
AC BREAKERS
(-60S Models)
VOLTMETER TO
READ VOLTAGE
IN AND OUT
OF THE MMP
ENCLOSURE
INV INV IN /
BYP INV OUT
AC BREAKERS
(-30D Models)
INV
BYP
120 V
AC OUTPUT TERMINALS
120 V
240 V
120 V
120 V
AC INPUT TERMINALS
120 V
240 V
120 V
(TO INVERTER LOADS)
(FROM UTILITY OR GENERATOR)
INV
OUT
INV
IN
MMPXXX-30D
MODELS
MMPXXX-60S
MODELS
Figure 3-28, AC Voltage Checks
© 2010 Magnum Energy, Inc.
Page 47
4.0 Operation
4.0 Operation
The MMP enclosure provides you with circuit breakers/disconnects to easily operate and maintain
your inverter/battery system. These breakers are used as the main power disconnecting means
and/or overcurrent protection. Refer to Figure 4-1 (MMP Functional Diagram) to see the functional
operation of the breakers within the MMP enclosure.
Info: Figure 4-1 is for descriptive purposes only, for specific wiring please refer to the
relevant wiring diagram in the Installation section of this manual.
Info: For information on operating the inverter, refer to it’s Owner’s Manual.
If a short-circuit condition occurs, or if a load is placed on these circuit breaker that is more than
its rated capacity, they will trip OFF (down). On the AC breakers, a red indicator will show through
the clear window on the circuit breaker to show a tripped condition. On the other circuit breakers
the handle will trip all the way to the OFF position.
Before resetting the breaker, first determine the cause of the overcurrent fault. Then, reset the
circuit breaker by turning it all the way OFF and then all the way back ON. For proper maintenance
and longer life, the circuit breakers should be turned off and on several times at least once a year.
This will help to prevent the contacts inside from sticking together.
To shut the MMP/Inverter System OFF completely, all of the circuit breakers in the MMP
enclosure should be switched to the OFF position.
INVERTER
(DC side)
DC NEG Busbar
N EG (-)
B A T T ER Y
BANK
(C ustom er
C onnection)
POS (+)
DC
B reakers
( optional )
DC Shunt
INV DC Breaker
DC POS Busbar
A C S id e
A C IN
AC
SOU R C E
F R OM M A IN
PA N EL
(C US TO ME R
C O NNE CTIO N )
DC
INPUT
M M P E n clo su re
EXTERNAL AC Terminal Block
D C S id e
A C OU T
AC BYPASS AC OUTPUT
AC INPUT
B reakers
IN V IN
ON
ON
OFF
OFF
INVERTER AC Terminal Block
AC
INPUT
DC
L OA D S
(C ustom er
C onnection)
AC
L OA D S
IN SU BPA N EL
(C US TO ME R
C O NNE CTIO N )
IN V O U T
AC
INVERTER
(AC side) OUTPUT
Figure 4-1, MMP Functional Diagram
Page 48
© 2010 Magnum Energy, Inc.
4.0 Operation
4.1 Inverter DC Disconnect Breaker
The Inverter DC Disconnect Breaker is used to disconnect the battery during battery maintenance.
This disconnect can also be used to protect the inverter, battery, and inverter DC cables from overloads and short circuits. The Inverter DC Disconnect does not, however, disconnect the battery
power from the Positive DC Busbar in the MMP enclosure, so, if you have installed any optional
DC load breakers, you must turn OFF all DC load breakers to disconnect battery power to all the
DC loads.
Before switching the DC Inverter Disconnect OFF, turn the inverter OFF. This is to protect
the inverter and other equipment from failure, and to preserve the contacts in the breaker.
WARNING: Do not use the Inverter DC Disconnect breaker to turn your inverter on
and off on a regular basis, it is there to provide safety and ease of maintenance. Turn
off the inverter at its on/off switch first. However, in an emergency, the Inverter DC
Disconnect is provided so that you can switch it off while the inverter is operating.
Info: Always switch the Inverter DC Disconnect to OFF before connecting or disconnecting
the battery bank, to reduce the chance of spark and wear on the connectors.
4.2 AC Input Breaker
The AC Input Breaker when switched ON, allows the incoming AC source (utility or generator) to
be connected to the inverter’s AC input. This breaker should be switched OFF to disconnect the
AC power from the inverter AC input.
On MMPxxx-30D models, this breaker is a dual-pole 30 amp circuit breaker (see Figure 2-3). On
MMPxxx-60S models, the AC input disconnect breaker is one-side of a dual 60 amp breaker; the
other side of this dual 60 amp breaker is used as the AC Output Breaker (see Figure 2-5).
4.3 Inverter AC Output Breaker
The Inverter AC Output breaker when switched ON, allows the AC power out of the inverter — either
inverter power or pass-thru power (from the utility or generator) — to be connected to the AC loads.
With this breaker OFF, the connected inverter loads beyond the MMP enclosure can be serviced.
On MMPxxx-30D models, this breaker is a dual-pole 30 amp circuit breaker (see Figure 2-3). On
MMPxxx-60S models, the AC Output disconnect breaker is one-side of a dual 60 amp breaker; the
other side of this dual 60 amp breaker is used as the AC input breaker (see Figure 2-5).
4.4 Inverter AC Bypass Switch Breaker
The Inverter AC Bypass Switch Breaker allows the inverter loads to continue to be powered by
the incoming AC source (utility or generator) while isolating the inverter or battery system if
maintenance or repair is needed.
This switch is pre-wired in the MMP enclosure between the incoming AC source and the inverter
load panel (i.e., sub-panel). It connects the incoming AC source to the inverter’s AC loads; either
through the “inverter” or directly by “bypassing” the inverter. This bypass switch assembly uses
a mechanical interlock between two AC breakers to prevent both breakers from being ON at the
same time, but both can be OFF at the same time. This Bypass switch is normally set to ‘OFF”
(inverter not bypassed), but can be easily moved to “ON” (bypass inverter) allowing the AC loads
to continue to be powered if the inverter or battery bank needs to be serviced/disconnected
– without any re-wiring.
Refer to Figure 4-2 (MMPxxx-30D models) or Figure 4-3 (MMPxxx-60S models) to review the
operational modes and power flow of the Inverter AC Bypass Switch.
All AC loads should be turned off before switching the Bypass Switch breaker.
Info: When the Bypass Switch is ON, the connected equipment is directly powered from
the AC source (utility or generator) and will go off if the AC source is disconnected or
turned off.
© 2010 Magnum Energy, Inc.
Page 49
4.0 Operation
SUB-PANEL
ON
OF F
ON
OF F
ON
O FF
ON
ON
OF F
O FF
ON
ON
OF F
ON
O FF
ON
OF F
O FF
MAGNUM
INVERTER
INV BYPASS INV OUTPUT INV INPUT
= ON
= OFF
= ON
MAIN PANEL
O FF
ON
OF F
ON
OF F
ON
ON
ON
OF F
ON
O FF
ON
O FF
O FF
ON
O FF
OF F
ON
OF F
Normal Operation
With the AC Breakers in this position, power passes
through the inverter to the connected loads. If an AC
line failure occurs, the inverter will use DC power from
the batteries to maintain the loads in the sub-panel.
OF F
ON
O FF
ON
ON
O FF
ON
ON
OF F
ON
ON
OF F
O FF
ON
OF F
BYPASS
SWITCH
SUB-PANEL
ON
OF F
ON
OF F
ON
O FF
ON
ON
OF F
O FF
ON
ON
OF F
ON
O FF
ON
OF F
O FF
MAGNUM
INVERTER
INV BYPASS INV OUTPUT INV INPUT
= OFF
= ON
= ON
MAIN PANEL
O FF
ON
OF F
ON
OF F
ON
ON
ON
OF F
ON
O FF
ON
O FF
O FF
ON
O FF
OF F
ON
OF F
Inverter Bypass Operation
With the AC Breakers in this position, power passes
directly to the loads in the sub-panel, bypassing the
inverter. When the Inverter Input breaker is ON,
the batteries will continue to be charged. If inverter
maintenance or service is required, the Inverter Input
breaker must be turned OFF. If AC power from the main
panel fails while the AC breakers are in this position, the
loads in the sub-panel will not be powered.
OF F
ON
O FF
ON
ON
O FF
ON
ON
OF F
ON
ON
OF F
O FF
ON
OF F
BYPASS
SWITCH
SUB-PANEL
ON
O FF
ON
OF F
ON
ON
O FF
OF F
ON
O FF
ON
OF F
O FF
ON
O FF
ON
ON
O FF
MAGNUM
INVERTER
INV BYPASS INV OUTPUT INV INPUT
= OFF
= OFF
= ON
MAIN PANEL
ON
OF F
ON
OF F
ON
O FF
ON
OF F
ON
OF F
ON
ON
O FF
O FF
ON
ON
O FF
O FF
O FF
OF F
O FF
ON
ON
ON
ON
ON
OF F
ON
O FF
ON
O FF
OF F
ON
O FF
BYPASS
S WITCH
AC OFF Operation
With the AC Breakers in this position, power from both
the main panel and inverter are removed from the
sub-panel. This allows the inverter, the loads in the
sub-panel or any installed equipment beyond the MMP
enclosure to be serviced.
Figure 4-2, MMPxxx-30D Bypass Switch Operation
Page 50
© 2010 Magnum Energy, Inc.
4.0 Operation
SUB-PANEL
ON
OF F
ON
OF F
ON
O FF
ON
ON
OF F
O FF
ON
ON
OF F
ON
O FF
ON
OF F
O FF
MAGNUM
INVERTER
INV
BYPASS
= OFF
INV INPUT &
INV OUTPUT
= ON
MAIN PANEL
O FF
ON
OF F
ON
OF F
ON
ON
ON
OF F
ON
O FF
ON
O FF
O FF
ON
O FF
OF F
ON
OF F
Normal Operation
With the AC Breakers in this position, power passes
through the inverter to the connected loads. If an AC
line failure occurs, the inverter will use DC power from
the batteries to maintain the loads in the sub-panel.
OF F
ON
O FF
ON
ON
O FF
ON
ON
OF F
ON
ON
O FF
ON
OF F
OF F
BYPASS
SWITCH
SUB-PANEL
ON
OF F
ON
OF F
ON
O FF
ON
ON
OF F
O FF
ON
ON
OF F
ON
O FF
ON
OF F
O FF
MAGNUM
INVERTER
INV
BYPASS
= ON
INV INPUT &
INV OUTPUT
= OFF
MAIN PANEL
O FF
ON
OF F
ON
OF F
ON
ON
ON
OF F
ON
O FF
ON
O FF
O FF
ON
O FF
OF F
ON
OF F
Inverter Bypass Operation
With the AC Breakers in this position, power passes
directly to the loads in the sub-panel, bypassing the
inverter. In this configuration, the sub-panel loads will
continue to be powered if inverter maintenance or
service is required. If AC power from the main panel
fails while the AC breakers are in this position, the subpanel loads will not be powered.
OF F
ON
O FF
ON
ON
O FF
ON
ON
OF F
ON
ON
O FF
ON
OF F
OF F
BYPASS
SWITCH
SUB-PANEL
ON
O FF
ON
OF F
ON
ON
O FF
OF F
ON
O FF
ON
OF F
O FF
ON
O FF
ON
ON
O FF
MAGNUM
INVERTER
INV
BYPASS
= OFF
INV INPUT &
INV OUTPUT
= OFF
MAIN PANEL
ON
OF F
ON
OF F
ON
O FF
ON
OF F
ON
OF F
ON
ON
O FF
O FF
ON
ON
O FF
O FF
O FF
OF F
O FF
ON
ON
ON
ON
ON
OF F
ON
O FF
ON
O FF
OF F
ON
O FF
BYPASS
S WITCH
AC OFF Operation
With the AC Breakers in this position, power from both
the main panel and inverter are removed from the
sub-panel. This allows the inverter, the loads in the
sub-panel or any installed equipment beyond the MMP
enclosure to be serviced.
Figure 4-3, MMPxxx-60S Bypass Switch Operation
© 2010 Magnum Energy, Inc.
Page 51
Appendix A - Optional Equipment and Accessories
Appendix A - Optional Equipment and Accessories
A-1
Installing a Remote Control
Complete the steps below to install the ME-RC or ME-ARC remote control on the MMP enclosure;
refer to Figure A-1 for assistance.
1. Unscrew the blank plate from the front cover, and remove the four 8-32 x 1/2 Phillips drive,
black colored screws taped to the back of this blank plate.
Info: The blank plate is attached to the front cover using #8-32 Hex nuts. Use a 11/32”
socket or wrench to remove/reattach these nuts.
2. Use these four screws and the four nuts that were used to hold the blank plate to attach the
remote control to the front cover.
3. Run the yellow colored remote cable that is provided between the remote and the Magnum
inverter/charger.
Info: The remote cable is a 4-wire, twisted-pair, telephony standard with 300-volt rated
insulation, and uses RJ14 (m) connectors on each end (see Figure 3-24). A standard
telephone cable would not be code-compliant and should not be used.
4. Connect one end of the remote cable into the RJ14 “REMOTE” port (has blue label) on the inverter/charger, and the other end into the RJ14 jack on the back-side of the remote.
BLANK
PLATE
FRONT COVER
(REAR VIEW)
FRONT COVER
(FRONT VIEW)
Figure A-1, Installing a Remote Control on the MMP Enclosure
Page 52
© 2010 Magnum Energy, Inc.
Appendix A - Optional Equipment and Accessories
A-2
Installing a Battery Monitor
MOUNTING DIMPLES WITH
#8 SCREW HOLES (X2)
SENSE MODULE
(PART OF ME-BMK-NS)
TWO #8 X 1/2”,
T15 TORX DRIVE SCREWS
(PROVIDED AND SCREWED INTO
THE TWO MOUNTING DIMPLES)
Figure A-2a, Mounting the Sense Module
To DC
N egative Busbar
black
To DC
Positive Busbar
Sen se M o d u le
(fro m M E-B M K)
4-Port T erm inal Block
(can be rem oved, and
each port accepts
30 to 12 AW G w ire).
D C Fu se (2 amp s)
red
D C Sh u n t
(in MMP Enclosure)
T o N etw ork Port
Tw isted-pair c able
red
black
orange
blue
T o Inverter/Loads
orange
C om m unications C able
(T o N etw ork Port on
M agnum inverter)
D C Po sitive B u sb ar
(in M M P En clo su re)
blue
C lo se- u p o f w irin g
th e M E -B M K
T o Battery Bank
D C N eg ative B u sb ar
(in M M P En clo su re)
Figure A-2b, Wiring the Sense Module and DC Shunt
© 2010 Magnum Energy, Inc.
Page 53
Appendix A - Optional Equipment and Accessories
A-3
MMP Backpanel Information
16
3
4
2
15
16
3
2 58 2 12
5
8
B
1 13
16
3 16
3
4
7
16
15
16
13 58
B
1115
16
16
B
111
16 2 1
16
B
1 21
7
11
3
4
3
8
15
16
32 83
3
3416
4
1 21
1115
16
B
11
11
B
4
3 12
11 34
B
1165
7
16
3
4
1
3
D etail A
B
1169
1161
3
4
B
1169
2167
7
416
3
4
3
4
A
9
116
1
15
16
5
16
3
8
9
116
3
8
B
1 21
1
316
15
16
5
16
Notes:
1. All dimensions are in inches.
2. Material = 16 gauge steel.
3. Finish = Powder coat white.
4. Detail B (x10) = PEM Nut (1/4-20).
5. Weight: 10.5 lbs. (4.8 kg).
14 78
6. Includes ten 1/4-20 x 3/4” Hex bolts; for mounting the MMP
enclosure, a Magnum Energy inverter, and the inverter hood.
7. The outside holes on the left and right side measure 16” center-tocenter. This allows the mounting plate to be secured to wall studs 16”
apart. If the wall studs are 24” apart, a minimum 3/4” plywood board
should be used to secure the backplate to the wall studs.
Figure A-3, MMP Backpanel (BP-MMP) Information
Page 54
© 2010 Magnum Energy, Inc.
Appendix A - Optional Equipment and Accessories
A-4
Installing Optional DC Breakers
The MMP enclosure provides the room to install additional DC circuit breakers that may be used
for charge controllers, a PV-GFP device, and other DC loads. This enclosure has been specifically
designed to allow both back mounted (1” wide)1 or DIN rail mounted (1/2” wide)2 breakers.
CAUTION: Turning the Inverter DC Disconnect breaker off only removes the battery
power to the inverter, it does not interrupt power from the battery to the DC load
breakers. This must be accomplished by turning off the DC load breakers themselves.
Therefore, to shut the system off completely, all of the breakers in the MMP enclosure
should be switched to the OFF position.
To install optional DC breakers inside the MMP enclosure:
1. Remove the front cover to the MMP enclosure.
2. For DIN rail mounted breakers
(refer to Figure A-4a):
For back mounted type breakers
(refer to Figure A-4b):
a. Install the breaker(s) on the DIN rail mounting
track, and slide all the way to the left side.
b. Place the breaker(s) on the DIN rail track, and
slide a DIN rail clamp tight against the right side
of last circuit breaker; and tighten this clamp to
secure the breaker(s) on the DIN rail track.
c. For each breaker installed, remove only 1
knockout (= 1/2” slot) in the front cover.
a. Remove the DIN rail mounting track by
unscrewing the two #8, T15 Torx drive
screws holding this mounting track.
b. Secure the breaker(s) to the panel using
two #8 screws, minimum 1/2” length.
c. For each breaker installed, remove
only 2 knockouts (= 1” slot) in the front
cover.
3. Ensure the breaker(s) align correctly into the spaces made by the knockouts removed from
the front cover.
4. Wire the breaker(s) to the DC circuit, use Figure A-4c to assist in wiring the breaker.
5. Replace the MMP front cover and check that the breaker operates correctly.
Note 1 - For the 1/2” wide DIN rail mounted breakers, use Q-Frame types (QYN Series by CBI).
Note 2 - For the 1” back mounted breakers, use E-Frame types (E Series by Carling Technologies,
209 Series by Airpax/Sensata Technologies or CF Series by Heinemann/Eaton).
D INDIN
R ARAIL
IL M MOUNTED
O U N T E DDC
D CBREAKER
B RE A K E R
(½
” WWIDTH
ID T H)
(1/2”
DDIN
IN RRAIL
A IL
M OMOUNTING
U N T IN G TRACK
TRA CK
Figure A-4a, Installing DIN Rail Mounted DC Breakers
© 2010 Magnum Energy, Inc.
Page 55
Appendix A - Optional Equipment and Accessories
SCREW TO BREAKER
MOUNTING PLATE
(REMOVE DIN RAIL)
TWO DC BREAKER
MOUNTING SCREWS
(USE #8 X 1/2”
LENGTH MINIMUM)
BACKPANEL
MOUNTED
DC BEAKER
(1” WIDTH)
Figure A-4b, Installing Backpanel Mounted DC Breakers
I N S ID E M M P E N C L O S U R E
P V C H A R GE
C ON T R OL L ER
(REMOVE THIS BUSBAR W HEN PV-GFP IS
INSTALLED TO PREVENT MULTIPLE CONNECTIONS )
D C S H UN T
G ROUND TO N EGATIVE CONNECTION
P V P A N EL S
B
PV PV
PV
PV
PV - G F P
B RE AK ER
P V I N PUT
B R EA KE R
P V O U TP UT
B R EA K ER
B
W IR IN G L E G E N D
NEGATIVE TO
GROUND
CONNECTION
USING PV-GFP
D C POSIT IVE
B U SB A R
D C N EGA T IVE
B U SB A R
D C GR OU N D
B U SB A R
T O BATTERY BANK
POSITIVE TERMINAL
(THROUGH DC S HUNT)
TO BATTERY BANK
NEGATIVE TERMINAL
TO PRIMARY DC
GROUND SYSTEM
DC G R O U N D
N E G A TIV E (-)
P O S ITIV E (+)
Figure A-4c, Wiring DC Breakers
Page 56
© 2010 Magnum Energy, Inc.
Appendix A - Optional Equipment and Accessories
A-5
Installing Lightning Arrestors
Unfortunately, in Renewable Energy (RE) systems where components are wired to outdoor electrical
systems, there is a greater chance of damage to these components from lightning strikes. Lightning
does not have to strike directly to cause damage, it can be far away and still induce power surges
or spikes in the wires of the RE system. Since the RE wires are connected to the conductors coming
into the house; the inverters, charge controllers, batteries, and other components in the house
or power shed are easily susceptible to damage.
The best line of defense against these high voltage surges — caused by lightning — is to ensure
you have proper system grounding. Proper grounding attempts to divert lightning surges to earth,
instead of going through your electrical components. However, for additional protection in lightningprone areas or where good grounding is not feasible, install lightning arrestors (also known as high
voltage surge arrestors) on the DC and AC circuits of your renewable energy system. Lightning
arrestors are devices that respond to voltage variations instantaneously, effectively intercepting
potentially damaging spikes and surges and reducing them to acceptable power levels to protect
electrical equipment. Metal Oxide Varistors (MOVs), Silicone Oxide Varistors (SOVs), and Zinc
Oxide Non-Linear resistors (ZNRs) are three types of lightning/surge arrestors.
The most readily available lightning arrestors in the marketplace install into 1/2’’ conduit knockouts.
Since the MMP enclosure is the central connection point for the main AC and DC electrical
components of the Renewable Energy system, multiple 1/2” knockouts are provided to allow these
lightning arrestors to be easily installed. The lightning arrestors should be connected as close to
the equipment you are trying to protect as possible. Review Figure A-5a for help installing these
lightning arrestors and use Figure A-5b for assistance on wiring lightning arrestors on the DC and
AC circuits inside the MMP enclosure.
Info: Install additional lightning protection (secondary lightning arrestor) if equipment
is more than 60 ft away from where the primary lightning arrestor is connected.
Info: For more information on lightning protection in RE systems, review Protection
Against the Effects of Lightning on Stand-Alone Photovoltaic Systems - Common
Practices at www.iea-pvps.org.
MMP
Enclosure
Lightning
Arrestor
½ ” knockout
rem oved
½ ” lock
w asher
Figure A-5a, Installing Lightning Arrestor on MMP Enclosure
© 2010 Magnum Energy, Inc.
Page 57
Appendix A - Optional Equipment and Accessories
N O TE : C RIMP A RING TE RMINA L
W ITH A 5/16" O P E NING TO THE
LIG HTNING A RRE S TO R W IRE S A ND
CO NNE CT TO THE M A G NUM
INV E RTE R D C TE RMINA LS .
F O LLO W THE P RO P E R D C
HA RDW A RE S TA CK A ND E NS URE
THE RE IS NO THING B E TW E E N THE
D C B US B A RS A ND THE
INV E RTE R ’S D C TE RMINA LS .
T O L IG HTNING
A RRE S TO R
T O I NV E RTE R
A C INP UT
T O P RO TE CT
A C INP UT TO
I NV E RTE R
T O P RO TE CT
D C INP UT TO
I NV E RTE R
L ig h tn in g
A rresto r
(A C rated)
L ig h tn in g
A rresto r
(D C rated)
S E RV ICE
E NTRANCE
CO NNE CTO R
( S P LIT BO LT )
AC
TE RMINAL
BLO CK
SIDE VIEW
T O P RO TE CT
INP UT TO
N O TE: T HE AC TE RMINA L B LO CK IS NO T RA TE D TO
CO NNE CT MO RE THA N O NE W IRE LA RG E R THA N #12
AW G. T HE RE FO RE TO CO NNE CT A L IG HTNING
A RRE S TO R, A S E RV ICE E NTRA NCE CO NNE CTO R (O R
S P LIT B O LT) IS RE Q UIRE D TO CO NNE CT B O TH THE
INV E RTE R ’S AC INP UT W IRE A ND THE LIG HTNING
A RRE S TO R W IRE TO THE AC TE RMINA L B LO CK.
E NS URE THE S E RV ICE E NTRA NCE CO NNE CTO RS A RE
INS ULA TE D FRO M E A CH O THE R TO P RE V E NT THE AC
INP UT W IRE S FRO M S HO RTING TO E A CH O THE R .
D C LO ADS
L ig h tn in g
A rresto r
(D C rated)
Figure A-5b, Wiring Lightning Arrestor to MMP Enclosure
Info: Make sure enough insulation is stripped so that the inverter’s AC input wire is
fully inserted in the AC terminal block and enough uninsulated wire is still available to
contact with the lightning arrestor wire when using the service entrance connector.
Info: Some readily used service entrance connectors are the Type SX manufactured
by Ilsco (www.ilsco.com), or the Type N manufactured by Thomas and Betts (www.
tnb.com).
Page 58
© 2010 Magnum Energy, Inc.
Appendix B - Warranty & Service
Appendix B - Warranty and Service
B-1
Limited Warranty
Magnum Energy, Inc., warrants the MMP enclosure to be free from defects in material and
workmanship that result in product failure during normal usage, according to the following terms
and conditions:
1. The limited warranty for the product extends for 36 months beginning from the product’s
original date of purchase.
2. The limited warranty extends to the original purchaser of the product and is not assignable or
transferable to any subsequent purchaser.
3. During the limited warranty period, Magnum Energy will repair, or replace at Magnum Energy’s
option, any defective parts, or any parts that will not properly operate for their intended use
with factory new or rebuilt replacement items if such repair or replacement is needed because
of product malfunction or failure during normal usage. The limited warranty does not cover
defects in appearance, cosmetic, decorative or structural parts or any non-operative parts.
Magnum Energy’s limit of liability under the limited warranty shall be the actual cash value of
the product at the time the original purchaser returns the product for repair, determined by
the price paid by the original purchaser. Magnum Energy shall not be liable for any other losses
or damages.
4. Upon request from Magnum Energy, the original purchaser must prove the product’s original
date of purchase by a dated bill of sale, itemized receipt.
5. The original purchaser shall return the product prepaid to Magnum Energy in Everett, WA. After
the completion of service under this limited warranty, Magnum Energy will return the product
prepaid to the original purchaser via a Magnum-selected non-expedited surface freight within
the contiguous United States and Canada; this excludes Alaska and Hawaii.
6. This limited warranty is voided if:
•
the product has been modified without authorization;
•
the product label and/or serial number label has been altered, defaced or removed;
•
the product has been damaged from abuse, neglect, accident, high voltage or corrosion;
•
the product was not installed and operated according to the owner's manual.
B-2
How to Receive Repair Service
If your product requires warranty service or repair, contact either:
1. An Authorized Service Center, which are listed on the Magnum Energy website at
www.magnumenergy.com/ServiceCenters-US.htm, or
2. Magnum Energy, Inc. at:
Telephone: 425-353-8833
Fax: 425-353-8390
Email: [email protected]
If returning the product directly to Magnum Energy for repair, you must:
•
Return the unit in the original, or equivalent, shipping container.
Note: Damage from shipping is not covered under warranty, ensure the unit is properly
packaged.
•
Receive a Return Materials Authorization (RMA) number from the factory prior to the
return of the product to Magnum Energy for repair.
•
Place RMA numbers clearly on the shipping container or on the packing slip.
BEFORE RETURNING ANY UNIT TO MAGNUM ENERGY INC.,
A RETURN MATERIAL AUTHORIZATION (RMA) NUMBER IS REQUIRED.
© 2010 Magnum Energy, Inc.
Page 59
Magnum Energy, Inc.
2211 West Casino Rd.
Everett, WA 98204
Phone: 425-353-8833
Fax: 425-353-8390
Web: www.magnumenergy.com
MMP Owner’s Manual (PN: 64-0029 Rev A)